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HARTING User's Guide Transportation - HARTING

1. 20 Ill 2 9 Han Easy Lock locking lever 21 HAN s n di Le e er 22 III 2 11 Housing DIN 41 612 IEC 60 603 2 26 IL 3 Hoods and Housings for EMC requirements 27 IL A Contact inserts and contacts 29 Weta Han d el 31 WAZ Han HC Miete 32 lll 4 3 Connectors in accordance with DIN 41 612 IEC 60 603 2 42 III 1 Ill Connectivity Products III 5 Power connectors III 5 1 III 5 2 III 7 Types of connections used in connectors III 1 III 2 III 3 III 4 III 5 III 8 Overview of tools and accessories III 8 1 III 8 2 III 8 3 III 8 4 III 8 5 III 9 Spare parts III 6 Han Yellock housing and contact inserts Power connector with one part housing Power connector with two part housing sui terminal ge Cage clamp terminal Han Quick Lock termination technique Crimp wire CONNECTION IIl 7 4 1 Crimp connections for wire cross sections or 10 240 mMM onun Ill 7 4 2 Connecting multiple strands in a single crimp contact
2. 56 Han HPR housing SIZE 3 A 1 erecta tron reee anas 57 Achieving IP 65 or IP 68 protection degree for bulkhead mounting housings 58 Contact inserts with O ring seal 59 Han Brid contact inserts A E eee kake ek kek eeekeee ee 60 Contact inserts with screw adapters 61 D 530 1 LOD SCCUON EE 62 V 36 2 ere 64 an NEBE II M E E ME NHEHEHH NENE MEDE DEDE M EDE DE ET ZM M MOAYM 68 Coding elements 72 IV 38 1 Coding with locking studs ssnnnnosseeenssssseeessseseessssseeeess 72 IV 38 2 Coding with guide pins and guide sockets 73 Locking panel for locking lever 75 Han M12 Crimp EEN 76 HARAX M12 L shielded os 78 rara A RIAS Z pou 79 Han 3 A RJ45 8 pole and RJ Industrial RJ45 82 IV 2 IV Installation Instructions eg HARTING IV 1 Installation Instructions This chapter contain instructions for the on site installation and assembly of the connectors that are most commonly used in the railway industry Some of the files are found in the catalogues Industrial Connectors Han and others
3. HBARTING Table Ill 7 1 Overview of contact inserts and wire connection types Screw terminal Han E Han HsB Han Hv E Han K 6 12 Han K4 x Han A9 Cage clamp connection Han ES Han ESS Han ES module Han K 4 4 control contacts InduCom9 MVB InduCom9 WTB InduCom9 CAN InduCom9 Profibus DIN 41 612 shape H15 Han Quick Lock connection Crimp connection Han C module Han 40 A crimp module Han 70 A crimp module Han 200 A crimp module Han HC Modular 250 Han HC Modular 350 Han HC Modular 650 only 240 mm Han Hv E an K 6 36 Han K 8 24 Han K 12 2 Han Q 5 0 Han Q 12 0 power contacts InduCom 9 InduCom D Sub DIN 41 612 Bauform F Axial screw connection Han Q 2 0 Han Q 2 0 High Voltage Han K 4 4 power contacts Han K 6 6 Han K 8 0 Han C axial module Han 40 A axial module Han 70 A axial module Han 100 A axial module Han 200 A axial module Han K 3 x Han HC Modular 350 Han HC Modular 650 These connection methods are described in the text below III 57 Ill Connectivity Products 2 2 272 727272 2 2 2 2 2 2 2 2 HARTING IL A1 Screw terminal The screw terminals are designed in accordance with DIN EN 60 999 A dis tinction is made between terminals with wire protection and terminals that offer no wire protection The wire protection mechanism consists of a metal tongue that is pressed down by the terminal screw onto the wire refer to Figure Ill 7 1 Th
4. IIl 62 Ill Connectivity Products e F z Q 1 HARTING Table Ill 7 4 Overview of the stripping lengths for cross sections 0 14 10 mm Wire cross section cross section Stripping length mm Han D Han E Han C DIN 41 612 D Sub Han DD Han A Han Modular Han Hv E Han Modular 10A 16A oaos a s 75 J 38 4 oso z e 75 J 35 Ta ors Te e 75 35 4 To te 8 75 TT 35 a5 3 s 7s TT 35 Te 8 7s ps 3o e TT 7s T9 j III 7Z 4 1 Crimp connections for wire cross sections of 10 240 mm Crimp contacts are available for wire cross sections from 10 to 240 mm They can be processed with crimp dies according to DIN EN 46 235 Thus crimping can be carried by tools which Can exert a pressing force of 130 kN or 13 tons Can be fitted with crimping dies according to DIN 46 235 Additional tools are not required III 63 III Connectivity Products ey HARTING Table lll 7 5 Stripping lengths 10 240 mm Contact Product article number Cross section Insulation strip mm ping length mm Han TC650 09 11 000 6167 6267 240 46 Han HC Modular 650 III 7 4 2 Connecting multiple strands in a single crimp contact It is not forbidden to crimp multiple strands in a single crimping sleeve In ord
5. Heating value Thermal fire load Selected fire protection standards that cover the contact inserts The specifications in the table refer to the contact inserts for industrial con nectors Flammability data for interface connectors DIN connectors and M12 connectors are available on request VII 8 LOL9L44N OLSSNIG OA Fein ez vioo vioo fareuoqueosjod ajew duo gz elnpoW OH UeH 1Z0E 100 LL 60 L0L9LJJN OLSSNIG OA v 61n 6 c 800 0 e1euoqieo jod i DOR 1 Gr n 080 0 apiwexjod ejeui9 duiuo 069 JejnpojN OH ueH LLLE LOO LL 60 L0L9LJJN OLGSNIG OA 61n 6 2 8000 OA v610 9 vY0 0 LOL9LJJN OLGSNIG OA F U 6 Z 00 0 OA 61n 9 Leon ZS0 0 S 0 0 L0L9LJ4N OLSSNIG OA v61n 6 Z 700 0 9jeuoqJeo jod OA be Ka 0070 00 spiurefqod jewu duld OGE 1eijnpoj y OH UeH LOOS 100 LL 60 8rv 0 8670 HARTING 9jeuoqJeo od opiueAqod jew duo 069 Jepo OH UeH 110 100 LL 60 ajyeuoqueodfjod opiueKqod ajeway duu ose Jejnpoy OH ueH LOLE 100 LL 60 epiue Jod V069 ZLW S NG OHI UeH SZZ 100 11 60 apiwedjod 2WWG81 OG1 V0G9 Xy ng oHI UeH ZZZZ LOO LL 60 06D O 9 esoo f sieo epiue pod u10 09 V0S9 Xv n8 2HI UH 0ZZZ 100 11 60 lt On 9 vevo 628 0 epiuueflod YOSE OLW S NG OHI ueH GGZZ 100 LL 60 GLE eplwedjod zWWOZ1 OZ VOS9 Xv ng oHI UEH LZZZ 100 LI 60 06D O 9 vevo solo epiue pod wwiozl G6 vOSE Xv nq oHI ueH
6. SS HARTING IV 17 Crimping tool 09 99 000 0377 Operating Instructions The Service Crimp Tool 09 99 000 0377 is designed for application of twisted HARTING contacts cross section range 0 6 and 10 mm For application of these contacts the crimp tool is equipped with a fixed turnable locator Ratchet Mechanism In order to ensure a constant crimp quality for all contacts the crimp tool is equipped with a releasable safety catch t prevents the crimp tool from closing before the crimping jaws are fully opened t prevents the crimp tool from opening before the crimp cycle is completed Early release It is possible to effect an early release of the safety device with a screwdriver if the crimp is faulty The safety device is released by turning right or left The load must be taken off the jaws by applying slight pressure to the handle Damage the crimping stamp will thus be prevented if the contact does not lie correctly in the profile Do not use force to open and shut the crimp tool Lubricate all moving parts weekly Locator The crimp tool is equipped with a locator for all specificities contacts Crimping Procedure Insert the contact into the proper crimpprofil until it is stopped by the locator Insert the stripping wire into the contact Crimp the contact by closing the handles untol the controlled cycle mechanism release Upon release the handles will open automatically and the crimped contact can be rem
7. rect position and is terminated as follows Assemble the contact roll 2 onto the roll holder 1 holding it in place with the knurled nut 3 ENSURE THE CONTACTS POINT e INWARDS TOWARDS THE ROLL 1 HOLDER L Ensure the crimp tool is fully open Insert the contact strip 6 4 in the direction of the arrow shown into the Indexing Unit Ensure the contact and the retaining plate of the Indexing Unit 5 is a over the contact and wire insulation as shown in the detail below Index the contact strip forward by pushing trigger 7 fully to wards the crimping head EN GH t Adjustment of Indexing Unit To produce a crimp contact within the Crimp Wire profiles as a and b it is necessary to adjust the Indexing Unit as follows Open knurled nut 9 Move the Indexing Unit to the left or right Tighten the knurled nut 9 Check whether the contact is positioned in the middle of the required Crimp Wire pro file as indicated on the tool Crimp process Care about the set up in 3 will produce a good crimp Index the contact strip with trigger 7 Insert the wire into the contact Close the hand tool completely until the safety ratchet clicks off to open Take out the crimped contact IV 40 IV Installation Instructions ee rq VAR BARTING Tip the empty carrier strip that feed out of the tool can easily be broken off at 8 Changing contacts Release the Indexing Unit Red R
8. II Connectivity Products s HARTING III 2 3 Han HPR housing size 3 A long version Figure lll 2 1 Han 3 A HPR hood and housing long version The HPR product line is newly enlarged by large versions of Han 3 A HPR hoods and housings Compared to the previous versions this hood and housing features a much larger cabling space It also has a M25 sized thread instead of the previous M20 thread It is now possible to design pluggable and compact solutions for data and bus cables e MVB WTB using the Han Brid Ouintax contact insert with IP 68 protection This is the first time that the housing is being offered with either feed through or threaded M4 tapped holes on the bottom side The assembly of the housing with the tapped holes is carried out from the connection side This reduces the chance of leaky seals in the area surrounding the retaining screws The dimensions of the flange on the housing are identical to the existing bottom section It is therefore possible to keep the existing dimensions for the holes and exchange older housing with the longer housing These new hoods and housings share the same technical specifications and characteristics that are valid for all HPR hoods and housings Please note that the hood and housing is available with either black chromate passivation or black powdered RoHS compliant coating The following variants are available Hood and Housing with black chromate pa
9. eez moo zeo o jeuoqueofod Aug YOL XV IN GOIN Z ueH 19 200 t 60 019144N OLSSNIG OA 610 on Tal en ung ereuogieofod steet dwi voy GOW Z ueH ZOLE Z00 t 60 019144N OLSSNIG OA 611 zezo Tal zg zio o ereuogieoKod jew dulo Wor GOW Z UeH Z00 Z00 tl 60 019144N OLSSNIG rein zezo eez og zoo fayeuoqueokjod V Ob S L1S GOW Z NYH 1092 200 fl 60 019144N 016SNIG rein en eez on ero o jereuogueofjod 3u snoH OCH je npojV ueH 1ZE0 100 tl 60 019144N OLSSNIG OA 611 An Tal eoo Leon ereuogieofod OZ di POOH 093 4eINPOW UEH ZY0 100 f1 60 019144N OLSSNIG OA 610 oun 6ez Zeng svo o fereuoqieakjod G9 dl POOH 093 je npoj ueH LZtO 100 1 60 019144N 016SNIG kein ren eez son 610 faxeuoqueokjod au duiio vO0Z GOW UeH LOLE 100 1 60 019144N OLSSNIG OA 611 toro oez oun 6100 fayeuoqueoAjod jew y du l o V002 GOW ueH 100 100 t 60 019144N 018SNIG rein en eez on Ten jaeuogeofod TO W ZLO uey 100 Z10 ZI 60 019144N 0186NIG OA 610 sizo 6ez 6000 vioo neuogeood 4 0 4 DUH LOLE Z00 ZI 60 019144N 0188NIG OA 610 sizo 6ez 6000 vioo neuogeo4od W L 0 ueH 100 Z00 ZI 60 019144N OLSSNIG OA 610 sizo eez 6000 vioo neuogeood 4 0 6 0 NVH LOLE G00 ZI 60 HARTING 019144N OLSSNIG OA 611 Lem 6ez 8000 gio eeuo
10. K 3 0 straight version with Pflitsch UNI M Dicht cable gland type 253281808 for cable diameters 15 18 mm Shielding OD max 17 5 mm i IV 10 IV Installation Instructions HARTING Installation in angled hood 19 40 024 0631 3 x M25 for Han K 3 0 Sheet 1 Han 24 HPR hood angled Tightening torque 8 10 Nm please see catalogue information Wi Blanking piece il mE Stripping length for Han K 3 0 angled version with Pflitsch UNI EMC cable gland type 2542820068 for cable diameters 15 18 mm Shielding OD max 17 5 mm IV 11 IV Installation Instructions qoin HARTING Installation in angled hood 19 40 024 0631 3 x M25 for Han K 3 0 Sheet 2 n E Ls ssl V C r d IV 12 IV Installation Instructions HARTING Installation in straight surface mounting housing 19 40 024 1231 3 x M25 for Han K 3 0 19 40 024 1271 3x M25 1 x M20 for Han K 3 2 an 24 HPR housings surface mounting 1 N STIR SS NN A 2 h E D n Han K3 0 F or _ K3 0 M Tightening torque 8 10 Nm please see catalogue information z SW5 daxda Stripping length for Han K 3 0 straight version with Pflitsch UNI EMC cable gland type 2542820068 for cable diameters 17 20 mm Shielding OD max 19 5 mm DK IV 13 IV Insta
11. TH OF Oe 148 6001 227 F male connector with right angled solder pins PL 2 with snap In clips OF 06 348 6901 222 H male connector with right angled solder pins PL 1 bey a i o Ob 1152911 222 All shell howsings fulfil NFF classification F1 l2 Details see catalogue Connectors DIN 41612 When not otherwise specified all components shown in Table Ill 4 4 are fully equipped with contacts Other requirement levels AFS and assemblies are avail able on request or refer to the HARTING Connector DIN 41 612 Catalogue III 45 Ill Connectivity Products e HARTING 11 5 Power connectors One of the major keys to saving time and money during the installation of railway motors and drives is taking advantage of a pluggable power connec tor solution Depending on the type of railway wagon the electrical and mechanical pa rameters are specified by different requirements The HARTING industrial connectors have a modular design that allows you to make many combinations of housings and contact inserts They can be used with shielded or unshielded cables The power connectors are based on sized 24B housings from the Han HPR series The variant with two part housing provides a high degree of conve nience and safety while processing shielded cables III 5 1 Power connector with one part housing In order to help the user with their selection the overview tables in this sec tion illustrate th
12. ZGZZ 100 11 60 r 0N6n O 9 veo o zao epuefod wwioZ Ge vOSe XV nq OHI ueH 1SZZ 100 11 60 r 0N6I 9 hoo ezro puue od wwGe 02 VOSE XV nq 9HI ueH 06 Z 100 11 60 r On O 9 Zenn fesso epiue pod 1089 ZLIN S nS 2HI UeH 8 92 100 11 60 r 0N6n O 9 Zenn on epiue pod 1081 081 V0S9 XV I1S OHI UEH Z92 100 11 60 r 0N6I O 9 zavo 9s o puue od UU0Z1 0Z V089 XV I1S OHI ueH 1297 100 LL 60 r 0N6I O 9 Zenn 9sgo epiweiod 110 09 V099 XV I1S OHI ueH 0 92 100 11 60 x lt On 9 zevo gozo apiwedjod YOSE OLIN S S OHL UEH GG9Z 100 11 60 0N6In O 9 zevo ze o epuefpod ulu1041 66 V08E Xv ns oHI ueH ZG9Z 100 11 60 0N6In O 9 zevo ogro epiue jod 10 G V0S Xv ns 2HI ueH 1692 100 LL 60 r 0N6I x 9 zevo voro speed uuu g 0Z V0S XV S OHI ueH 069 100 11 60 UNI 33 fIN 83 i uon1od 9 QBUJUJB JJ uon1o Jaw spyepueig SIT len SUSE Far PET Jeuue1e N uondiJosep 140ug Jaquinu Wed peo oil EUJJ9U V r Jo 1ug19M VII Selected Standards Relevant to Railway Applications VII 9 019144N OLSSNIG OA 610 on sz moo Sz00 feyeuoqueoAjod V Ov S n8 GOW Z NYH 1042 Z00 f1 60 019144N 016SNIG OA 610 een J eez em zoo jewuoqueo Kod uuuGz 01 vO0l S ILS GOW Z NYH 592 Z00 fl 60 LOL9LAAN 016SNIG OA 610 osso 6ez zoo 6900 faxeuogqueosjod uuuce 91 v00l S ILS GOW Z NYH 1997 200 vl 60 019144N 016SNIG OA 610 ezo
13. 5 till the gauge pin slides easily into indenter opening without play or sloppiness Tool is now ready IV 29 IV Installation Instructions i i i i i i 3 ALLLB HARTING DO NOT CRIMP GAUGE PIN DAMAGE TO TOOL MAY FOLLOW The following chart shows the settings of gauge pin corresponding to the wire gauge mm ru a Lo 5 zo zo Usage of contact 09 15 000 6107 6207 GRIMPING 1 Insert contact and prepared wire through the open indenter A and into the locator 2 Squeeze handles together until positive stop is reached Tool will then re lease and return to the fully open position 3 Remove crimped contact and wire and inspect crimping GAUGE PIN Attached chart shows gauge pin diameter and corresponding part number In one tool few diameters are implemented REMARK We prohibit the use of this tool for every other application IV 30 IV Installation Instructions A HARTING IV 14 Hand crimping tool 09 99 000 0110 Operating Instructions The Service Crimp Tool 09 99 000 0110 is designed for allpication of twisted HARTING contacts cross section range 0 14 4 0 mm For application of these contacts the crimp tool is equipped with a fixed turn able locator Ratchet Mechanism In order to ensure a constant crimp quality for all contacts the crimp tool is equipped with a releas able safety catch e t prevents the crimp tool from closing before the crimping jaws ar
14. AWG 12 For Han D contacts For Han E contacts For Han C contacts For Han Yellock contacts Han D Han ER Han C Han Yellock contacts Only the male contact 09 15 000 6107 or the female contact 09 15 000 6207 should be used for wire cross sections of 0 14 and 0 25 mm2 III 67 Ill Connectivity Products E n HARTING Product photo Crimping tool Crimping tool For coaxial contacts 09 99 0000503 Attention Crimp dies must be ordered separately Crimping die For crimping tool Ji 09 99 0000508 09 99 000 0503 Wen Crimping tool For D Sub contacts 61 03 600 0022 Wire cross section 0 08 0 82 mm AWG 28 18 Attention Locator must be ordered separately Locator For crimping tool 61 03 600 0022 61 03 600 0023 AWG 28 20 61 03 600 0024 AWG 20 18 TK crimping Han D Han E contacts machine Wire cross section 09980006000 10 34 4 0 mm AWG 22 12 Performs both stripping and crimping processes Refer to the Han Industrial Connectors Catalogue Crimpautomat TC contacts Han D Han E Han D and Han C 09 98 000 9001 Wire cross section Han E 0 14 6 0 mm 09 980009002 AWG 26 10 Han C Performs crimping 09 98 000 9003 Refer to the Han Industrial Connectors Catalogue HARTING pneumatic Wire cross section crimping tool Han 0 14 1 5 mm 09 99 000 0810 AWG 26 AWG 16 Han E 0 14 4 0 mm Tool heads Refer to AWG 26 AWG 12
15. AWG 26 22 shielded 0 34 0 5 mm2 AWG 22 20 Insulation displacement connection Can be assembled on site Connection with piercing contact to wire Han 3 A RJ45 Wire diameter AWG 42 7 22 7 Outer diameter of cable 6 5 6 9 mm Degree of protection IP 65 IP 67 Can be assembled on site Connection with piercing contact to wire HARTING RJ Industrial Wire diameter AWG 42 7 22 7 Outer diameter of cable 6 5 6 9 mm Degree of protection IP 20 Table V 2 5 Overview of panel feed throughs and device interfaces Han M12 panel feed Female D coded shielded through for installa 360 mm cable AWG 26 4 pole tion outdoors Han M12 panel feed through for installation indoors Female D coded shielded 700 mm cable AWG 20 4 pole HARAX panel feed though Female D coded Male multi point connector crimp contacts 9 pole Han M12 PCB adapter Female D coded angled 4 pole Additional lengths available on request V 10 V Ethernet Networking Systems P TT M HARTING Table V 2 6 Overview of connectors for wagon couplings Produ Features Product photo Housing suitable for stricter climatic Han HPR hood requirements IP 69 K Available in different sizes with straight or angled cable outlets _ Housing suitable for stricter climatic Han HPR bulkhead requirements IP 69 K Available in different mounti
16. ETATS Switch series e Ethernet Switch per IEEE 802 3 Fast Ethernet 100 Mbit s Gigabit Ether net 1000Mbit s Mns eCon Store and forward switching mode asic functions unmanaged Auto Negotiation Auto Crossing Auto Polarity Up to 10 ports copper and fibre optic M12 and RJ45 Port characteristics and functions can Ha VIS sCon easily be configured via the USB port configurable functions For example redundancy parallel or ring configurable f f Up to 10 ports copper and fibre optic Management Services IGMP Snooping QoS VLAN RSTP 802 1x Link Aggregation DHCP Option 82 Ha VIS mCon management functions managed Web Management SNMP Management Up to 10 ports copper and fibre optic The switch is specially designed for use in rolling stock applications It com plies with the requirements of EN 50 155 regarding EMC temperature range and mechanical stability V 7 V Ethernet Networking Systems Table V 2 3 Overview of active network components Functional Un managed Unman aged with con figuration options via USB port Ha VIS eCon 3000 Ha VIS eCon 4000 Ha VIS eCon 7000 Ha VIS eCon 9000 Ha VIS sCon 3000 e 6x 8x 10x 10 100Base T X RJ45 Ports and optional 1x 2x 100Base FX fibre optic ports Robust metal housing IP30 Mounting on top hat rail Compact and thin design 8x 10 100Base T X ports M12 D coded 110 V DC and PoE variants Ro
17. Ill Connectivity Products Ill 8 Overview of tools and accessories Table lll 8 1 Crimping tools o HARTING Product photo Crimping tool standard crimping tool 09 99 000 0110 Locator Han Yellock 09 99 000 0341 Crimping tool 09 99 000 0303 Crimping tool 09 99 000 0377 Wire end ferrules crimping tool 10 mm 09 99 000 0374 Wire cross section Han D 0 14 1 5 mm AWG 26 AWG 16 Han E 0 5 4 0 mm AWG 20 AWG 12 Han C9 1 5 4 0 mm AWG 16 AWG 12 Han Yellock 0 5 4 0 mm AWG 20 AWG 12 Wire cross section Han C 6 mm AWG 10 Wire cross section Han C 6 10 mm AWG 10 8 Wire cross section 10 mm and 16 mm AWG 8 and AWG 6 Allows direct connection of 10 mm wire end ferrules to the existing Han Modular hinged frame Ill 66 Ill Connectivity Products HARTING Product photo Crimping tool Buchanan four point crimping tool 09 99 000 0001 Locator for the Buchanan four point crimping tool 09 99 000 0311 09 99 000 0310 09 99 000 0308 09 99 000 0342 Adjusting pin for the Bu chanan four point crimping tool for setting the crimping depth 09 99 000 03791 1 Han D contacts Wire cross section Han D 0 14 2 5 mm AWG 26 AWG 14 Han E 0 14 4 0 mm AWG 26 AWG 12 Han C 1 5 4 mm AWG 16 AWG 12 Attention The locators and adjusting pin must be ordered separately Han Yellock 0 14 4 0 mm2 AWG 26
18. SE CL 96 04 SE 04 SE 04 SE l2 0 S 04 SE HED pus BneB 9JIM ujBue Duddue 0S9 Je npo N OH eUEH JEINPOW OH UBH J0J oejuoo DUDOIE OSE Je npo N OH eUEH pejBue ZC queH JuBiens Z M eueH pejBue 0 3 sueH uB eJ s OCH eueH IV 7 IV Installation Instructions 9 ees HARTING The insulating base dimension ISK for the cable marking Marking the proper cable position for the axial screw connection contact point The user can attach a marker to the cable sheathing in order to specify the proper point for tightening the axial screw on the connecting cable If the cable in pushed into the insulating base up to the marker where the marker is flush with the upper edge of the insulating base then the cable is in the proper position and may be connected The Figure IV 2 1 illustrates this pro cess when using the Han HC Modular 350 contact The marker and the up per edge of the insulating base are at the same level as indicated by the LZ dashed line 1 Insulation stripping length 2 Insulating base dimension ISK dimension 3 Max cable insulation diameter 4 Inlet line Figure IV 2 1 Explanation dimensions using the sample of Han HC Modular 350 IV 8 IV Installation Instructions HARTING IV 3 General installation information for contacts in the axial screw connection Observe the following when connecting cables to contacts with t
19. SW 5 09 99 000 0371 350 A contacts SW 5 09 99 000 0372 650 A contacts SW 8 Assembly tool For contact inserts with caged 09 99 000 0367 tension spring connection Assembly tool For BC contacts 09 99 000 0100 Assembly tool For FC1 FC2 and FC3 09 99 000 0088 contacts Allen hex screw For housings with hex head driver with ball SCrews head 61 03 600 0021 Assembly tool For crimp flange installation 61 03 600 0017 D Sub housing 9 37 poles 61 03 600 0018 D Sub housing 50 poles 1 SW spanner width III 2 Ill Connectivity Products SOS HARTING III 8 1 Mounting frame for Han housing Table Ill 8 5 Mounting frames for Han housing Product photo Mounting frame For strengthening the mounting surfaces For housing Han B Intended for use with Sizes Han B housings and 6 B 09 40 000 9921 Han HPR housings 10 B 09 40 000 9922 Sizes B 24 B on thin 16 B 09 40 000 9923 walled panels 24 B 09 40 000 9924 We recommend using For Han HPR housing the mounting frame Sizes when installing multiple 6 B 09 40 000 9901 housings in a row 10 B 09 40 000 9902 16 B 09 40 000 9903 24 B 09 40 000 9904 III 3 Ill Connectivity Products s9 2 2 2 2 2 2 LL LGGG Ga HARTING III 8 2 Coding elements If an application is using multiple connectors of the same type then it is very important to take steps to ensure that the connectors cannot be mixed up and co
20. aa IV 50 IV Installation Instructions Per T HARTING Stripping length with crimp flange green while 11 green iz orange white 2 orange EI biuestwhite 5 s push back the shield nium Gi Eee brown while 7 brown Kah pearing a ETAITLA BARA salripoinao length with cable clamp greenwhie 1 green ixi orangewhite 3 Grande amp E ob b oie de ee e s de el een ul le e Cal le ak Col ae a a bluehwhite 5 fold the shielding over the wira bi n itj brownewhite 7 bros LT wiring acc ELATIA 568A IV 51 IV Installation Instructions HARTING IV 29 Han 46 EE Multiplier The contact insert should be inserted into the bulkhead mounting housing from the plug in side Figure IV 29 2 Be sure that you have already mounted both PE panels Figure IV 29 1 Note The PE panel is already attached to the contact insert 1 Figure IV 29 1 Figure IV 29 2 Han 46 EE multiplier top view Han 46 EE multiplier side view The multiplier is plugged with the contacts from the connection side into the contact insert that is mounted into the bulkhead mounting housing refer to Figure IV 29 3 Figure IV 29 3 Han 46 EE multiplier IV 52 IV Installation Instructions EEN HARTING Four M3 retaining screws Figure IV 29 4 are used to fasten the multiplier to the contac
21. are available separately upon request in PDF format General Notes It is the customer s responsibility to evaluate the suitability of the compo nents described here and the applicability of the specified regulations for use in any special applications which have not been anticipated by HARTING HARTING reserves the right to make construction changes in response to manufacturing requirements improved quality or advances in the design This information describes the components but should not be considered as a guarantee of certain properties Additional information can be found in the catalogues Industrial Connectors Han Device Connectivity and Ethernet Network Solutions Automation IT IV 3 IV Installation Instructions 9 M HARTING IV 2 Contact inserts with axial screw wire connection The axial screw connection was designed by HARTING for connecting wires with large cross sections In compliance with the HARTING philosophy no special tools are required for the connection Finely stranded wires can be safely connecting using a conventional hexagon torque wrench Table IV 2 2 gives an overview of wire cross sections stripping lengths and required torques for the listed contact inserts using the axial screw connec tion method The illustration Figure IV 2 1 shows the designations used for the dimensions The specified cross sections of the wires refer to the geo metric cross sectional area of the cable being used The sp
22. ing is installed in a similar fashion as the HPR housings in sizes HPR 6 B 24 B A mounting frame for the housing is not required because of the small dimensions Retaining hole M O ring seal Figure IV 32 1 Han 3 A HPR The bulkhead mounting housing is delivered with an additional seal in the plug in area Since the insulating bases of the sized 3A plastic inserts also have their own seal these seals must be removed before assembly The angled bulkhead mounting housing is delivered with a rubber flange seal The seal has through holes that are positioned for the retaining screws This poses a risk that moisture can penetrate into the housing through these retaining screws Thus the customer must provide an appropriate seal for the retaining screws Retaining hole covered Retaining hole with rubber flange seal Pd Figure IV 32 2 Figure IV 32 3 Han 3 A HPR Han 3 A HPR rubber flange seal rubber flange seal detailed view IV 57 IV Installation Instructions HARTING IV 33 Achieving IP 65 or IP 68 protection degree for bulkhead mounting housings The following requirements are necessary for ensuring that IP 65 or IP 68 protection is maintained when installing the bulkhead mounting housing in accordance with DIN 4766 Coarseness of the mounting surface Ra x 16 um e Undulation lt 0 2 mm over 200 mm distance The following torque is reco
23. monobloc and or Han Modular of size 16 B Option for pre assembly and for inspection of pre assembled cables before the final installation III 14 Ill Connectivity Products SSS HARTING Assembly illustration for the Han 48 HPR housing Upper cover Distance bolt Upper frame Contacts Hood Housing surface mounting Bottom frame Contacts Distance bolt Bottom cover ndi Figure IIl 2 7 Han 48 HPR assembly III 15 Ill Connectivity Products S n HARTING III 2 6 3 Han 48 M hood and housing This housing series is one of our product lines that can be used on the out side of railway wagons The locking lever for the bulkhead mounting housing and surface mounting housing has been fitted with an extra ratchet Spe cially designed to meet the requirements of the railway industry this ratchet must be actuated before opening the locking lever This prevents the connec tor from accidentally opening The products listed below feature an extra ratchet on their locking levers Article number 09 37 048 0311 Han 48 M bulkhead mounting housing protective cap 19 37 048 0298 Han 48 M surface mounting housing 2 x M40 protective cap 19 37 048 0299 Han 48 M surface mounting housing 2 x M50 protective cap The specification sheets for these housings are available on request Figure Ill 2 8 Figure IIl 2 9 Han 48 M assembly locking lever with Han 48 HPR
24. sizes 10 B 16 B 24 B Locking panel for Han Easy Lock For Han B bulkhead mounting No illustration lengthwise lever On request housings sizes 6 B 10 B 16 B 24 B 7 Han Easy Lock X Locking clamp is for use in harsh environmental condi tions It can only be delivered as a spare part 2 Locking panel The panel is simply put over the locked lever and the flex ible tongue snaps in For removal the tongue is pressed in with a screw driver IIl 86 Ill Connectivity Products e S SISOS HARTING Flange seal Material NBR FPM 09 20 000 9991 09 37 000 9912 09 20 000 9992 09 20 000 9993 09 20 000 9994 09 30 000 9991 09 30 000 9992 09 30 000 9993 09 37 000 9948 09 30 000 9994 09 37 000 9949 09 30 000 9996 Flange seal self retaining Material NBR 09 30 000 9801 09 30 000 9802 09 30 000 9803 09 30 000 9804 Gasket Size Material NBR FPM 09 70 000 9991 09 21 000 9906 3 A mounts on male insert 09 20 000 9996 10A 09 20 000 9997 16 A 09 30 000 9941 6B 09 30 000 9942 10 B 09 30 000 9943 16 B 09 30 000 9944 24 B 09 30 000 9995 48 B Han HPR O ring seal Size 09 40 000 9910 HPR 3A 09 40 000 9911 HPR 6B 09 40 000 9912 HPR 10 B 09 40 000 9913 HPR 16 B 09 40 000 9914 HPR 24 B 1 For Han A and B housings 2 For Han M housings 3 Only suitable for Han B bulkhead mounting housings with retaining surface of flange 4 For Han HPR housing Flange seal Used only with bulkhead moun
25. uonjod jqewwe y uonJo Lou spyepue1g s AAR ebe SEN IEUSa1EN uo 1diu9s p 140ug Jaquinu Wed peo oil EUJ9U an Jo 1ug19M VII 12 019144N OLSSNIG OA 610 n Ia 019144N OISSNIG OA 610 osso Ia 019144N OLSSNIG Dein 1290 ler 019144N OLSSNIG OA 610 ei eez 019144N OLSSNIG OA 610 oe J eez HARTING 019144N OLSSNIG outen Joe eez 019144N OLSSNIG OA 610 gen eez 019144N 016SNIG OA 610 mei eez 019144N OLSSNIG OA 610 oesi Ia 019144N OLSSNIG outen sier Ia 019144N 016SNIG OA 610 ii Ier 019144N OLSSNIG OA 610 gen eez 019144N OLSSNIG OA 610 0980 eez 019144N OLGSNIG OA 610 iO Ia 019144N OLSSNIG OA 610 6990 Ia LOL9LAAN OLSSNIQ OA YIN al Ier 019144N OLSSNIG OA 610 ezert eez 019144N OISSNIG OA 610 s rt J eez LOL9LAAN OISSNIG OA 610 zego J ez f En uonuod ajqewwey PAM OW spJepuej1g 14819m anjen Suneau SE peo eJij IEUUSaul eH VII Selected Standards Relevant to Railway Applications 9600 600 9600 9 00 960 0 600 IYOO 8 00 790 0 600 ZOO Ly 0 0 9 0 0 L 0 0 8200 GZ0 0 ZOO 060 0 680 0 20 0 610 0 910 0 10 0 800 0 EI uonJod 9 qeuue J Jo 1ug19M Ly 0 0 S00 Lv0 0 600 400 9 00 900 600 6400 0400 900 960 0 LG0 0 9v0 0 v0 0 Lo 690 0 990 0 800 880 0 AAKO 070 6600 800 0 Q o Q e o E
26. 0 EE 60 COLG vc0 EE 60 9197 V 0 EE 60 2092 vc0 EE 60 9127 910 E 60 ZOZZ 910 60 919 910 60 09 910 60 91Z2c 010 EE 60 0Z 010 EE 60 919 010 EE 60 2092 010 60 9122 900 60 Jequinu yed VII 14 VII Selected Standards Relevant to Railway Applications eae SSS i lt HARTING Notes VII 15 VII Selected Standards Relevant to Railway Applications gems qu H HARTING Notes VII 16 HARTING Electric GmbH amp Co KG Wilhelm Harting StraBe 1 32339 Espelkamp Germany P O Box 1473 32328 Espelkamp Germany Phone 49 5772 47 0 Fax 49 5772 47 124 electric HARTING com www HARTING com Subject to alterations without notice User s Guide Transportation Status 2010 09 English Printed in the Federal Republic of Germany ptm HARTING impos Pushing Performance www HARTING com MO 2010 09 17 1 5 98 48 911 0201
27. 03 278 4805 222 R female connector with right angled solder pins PL 2 Bs OF 73 296 301 222 2B male connector with right angled solder pins PL 2 He Ul M D m Ahh TN Ala 2C male connector with right angled solder pins PL 2 Sch N _ B male connector with right angled solder pins PL 2 09 22 132 6921 222 09 23 148 6921 222 09 92 164 6921 222 male connector with right angled solder pins PL 2 03 03 196 6921 222 M male connector with right angled solder pins PL 2 order special contacts separately 09 03 178 6901 222 R male connector with solder ping 4 0 man FL 2 03 73 196 6903 222 III 44 Ill Connectivity Products DIN Power D female connector with solder nins 4 4 mm PL 09 04 232 6831 223 E female connector With pressi pind 115 mm PL Z DN 05 248 8951 227 F female connector with soldar pins 4 5 mm PL 2 po cC D9 06 248 5835 222 TTE ar i _ how pralile P 09 05 248 6834 227 F female connector Tar crimp contacts DN D 248 3201 227 H female connector far faston 6 3 x 3 5 PL 1 DN D 215 2371 222 law pratile U9 06 glo 2321222 Shell housings with solder pirs 4 0 mm D male connector with right angied solder pins PL 2 OF 04 132 6921 222 E male connector with right angled galder ping PL Z F male connector with right angled solder nins PL z OF 05 148 6921 222
28. 2 requirements level 1 InduCom connector and D Sub are subject to the DIN 41 652 IEC 60 807 directive Insulation resistance gt 10109 O Mating cycles 2 500 mating cycles hazardous gas test CECC 75 301 802 requirements level 1 III 29 Ill Connectivity Products o HARTING Han multi pole contact inserts HARTING offers a variety of multi pole contact inserts with from 2 to 108 poles for use within the industrial connector The contact inserts are de signed for rated currents from 10 to 40 A Han Com combination connector Many applications require one connector that combines both power trans mission and control signal transmission The Han Com series of contact in serts provide for a great variety of combinations For high power requirements rated currents from 16 to 200 A can be car ried For control applications the rated currents range from 10 to 16 A The following directives regulate the consolidation of multiple circuits into a single cable or connector DIN EN 60 664 1 8411 1 3 2 and DIN EN 60 204 11 98 14 1 3 The designation of the contact inserts describes the contacts in use The ex ample given here is the Han K 4 8 e Han industrial connector Han K Han K Han Com series number of power contacts number of control contacts III 30 Ill Connectivity Products G MM a 9 HARTING III 4 1 Han Modular This series features many modules that satisfy a variety of customer
29. 6000 6200 jneuoqieofod 9 V xeiuImo 8 UEH EL0 800 SI 60 LOL9L44N OLGSNIQ OA 610 dd 662 6000 zzo o fayeuoqueohjod o nq xeIUIND f UEH ELLE 700 SI 60 L019143N OLSSNIG OA Fein DR 662 8000 68200 fareuoqueohiod 9 148 XEIUIND t ueH 0 v00 SI 60 L019143N 01SSNIG OA Fe 8690 sz S200 szo o jareuoqieofiod POW OZ URH LOLE OZO Fl 60 019144N OLSSNIG OA 610 Burn eil zoo zoo jneuqmofod WOW OZ ue 100 020 vl 60 LOL9L44N OLSSNIG OA 610 970 ez moo moo jayeuoqueofjod VOI 9 ng POW Z ueH LOLE ZLO YL 60 019144N OLSSNIQ OA Fe 612 0 ez 6000 600 0 s18uoqJeofjod YOL 9 I1S POW ZL ueH 100 Z10 fl 60 019144N OLSSNIG OA 610 970 6 z moo L jayeuoqueofjod VOL 9 n8 GOW ZL NYH LOLE ZLO 1 60 LOL9L44N OLSSNIG OA v61n 970 eez M00 moo jayeuoqueofjod VOL 9 I1S GOW ZL NYH 100 ZLO fl 60 019144N OLSSNIG OA 610 970 eez moo L jayeuoqueofjod V9 9 nq POW ueH LOLE 800 Y1 60 L019143N OLSSNIG OA 610 970 662 moo ioo jereuoqueofiod va pe POW 8 UEH 100 800 rl 60 L019133N OLGSNIQ OA Ke 970 6cz um ioo fareuoqueofjod 1euoissSunuunjeq 5 ng pow 9 ueH Tute 900 v 60 LOL9L44N OLSSNIG OA 610 970 eez oo moo jayeuoqueofjod va 9 ng PON 9 ueH LOLE 900 YL 60 019144N OLSSNIG OA 610 482 0 6ez Zen Zoo jeeuoqieoKod jeuorssSunuunueq 5 ns POW 9 UeH Ire 900 Yi 60 UNI Sx W Sal i
30. IT and Connectors DIN 41 612 It is explicitly stated that users have to comply with the relevant safety re quirements Research and standards are constantly evolving and driving the current state of technology HARTING has taken great care to ensure that this information is current and state of the art The user is nevertheless obligated to verify by means of standards and other original documentation that the informa tion presented herein does not deviate in any way with this original documen tation or with the particular application HARTING does not guarantee and is not liable for the correctness complete ness and timeliness of the applications HARTING is not liable for direct or indirect damages including loss of revenue resulting from the use of the in formation found in these application instructions unless unlimited liability is mandatory by statutory laws The components should only be used for commercial purposes Please note that usage for private purposes is not appropriate All rights are reserved by HARTING including the translation copying use of illustrations remote transmission photocopying or similar reproductions and computer archiving whether in whole or in part The reproduction of patented names trade names trademarks etc does not entitle that those names without special marks as defined by trademark and trade protection legislation can be regarded as freely usable by everyone German
31. SSS i i i i i i HARTING CERTIFICATE The DQS GmbH Deutsche Gesellschaft zur Zertifizierung von Managenmentsystemen hereby certifies that the company HARTING Electric GmbH amp Co KG Vili imi erm gr res L D 32339 Espelkamp for the scope Cabling and Cabinets IRIS Scope 12 Desgn manufacturing and sakes of industrial connectors Intertace and PCB connectors cable assemblies Fibreaptic systerns and companerits has implemented and maintains a Quality Management System An audit dccurmaerrbecl ina rior haa vain that has quality management ayatam fulfills the requirements of the following standard International Railway Industry Standard IRIS Revision 01 November 2007 Cenificaton audit 2009 02 27 Cenificaton decision 2008 04 26 Thi certiicate is valid until 2012 04 25 Cerificate Registration No 241244 IRIS issued in Frankfurt am Main Germany 2009 04 25 ar F E Jew iur N Drecinei Za Pop A RAMA AC M DHRECTORS IR IS j D 5043 3 Fank am Map Augusr Sena Smate 21 Certification VII 6 VII Selected Standards Relevant to Railway Applications F n QR ONv T Ss5 lt x5 c c1XX sA s t o a p c qs s 7sb q v HARTING VII 1 4 Flammability directives Trains are considered one of the safest modes of transportation throughout the world Standards governing flammability protection are a significant con tribution t
32. The railway standard EN 50155 3 VII 1 3 Additional standards 4 VII 1 4 Flammability directives 7 v VII 1 VII Selected Standards Relevant to Railway Applications 3 SSES HARTING VII 1 Selected Standards Relevant to Railway Applications The standards and directives that HARTING uses to develop design manu facture and test its connectors are listed below Particular attention has been given to all flammability directives that relate to HARTING contact inserts Vil 1 1 Connector standards The following international standards cover the general design of the connec tor and the termination method Interface DIN connector D Sub DIN 41 652 Connectors for plug in boards e CECC 75 301 802 Harmonized system of quality assessment for electronic components IEC 60 807 Rectangular connectors for frequencies below 3 MHz DIN 41612 e IEC 60 603 2 Connectors for printed circuits for frequencies below 3 MHz Industrial connectors IEC 61 984 Connectors Safety requirements and tests IEC 60 664 1 Insulation coordination for equipment within low voltage systems Part 1 Principles re quirements and tests e DIN EN 175 301 801 Detailed specification high pole rectangular connectors with round replaceable crimp con tacts for contact
33. This hood makes it significantly easier to install connectors It can be separated and this provides the best handling when working with large cable cross sections and or with high pole contact inserts Additional advantages include Quicker installation times he wiring is visible within the connection area An integrated cable gland Strain relief mechanism Captive screws Cable outlet with optimized angle The hood is available in sizes 16 B and 24 B It can fit on all corresponding housing by means of two locking levers Cable seals for a range of cable di ameters are available separately HARTING also offers threaded adapters for M25 and M32 as an extra accessory Figure lll 2 3 Han Easy Hood III 11 Ill Connectivity Products y HARTING III 2 6 Han HPR and Han M hood and housing HARTING also offers many customer specific hood and housing variants in addition to the wide variety of hoods and housings available in the Han B Han M and Han HPR series as detailed in our catalogue Industrial Con nectors Han Several examples of such customized products are described below the Han 24 HPR enlarged the Han 48 HPR and the Han M size 48 series with ratchet on the locking lever III 12 Ill Connectivity Products S SOS HARTING III 2 6 1 Han 24 HPR enlarged hood and housing L Figure lll 2 4 Han 24 HPR enlarged The Han 24 HPR series offers a pluggable
34. and 32 B 48 B I D II E E BB M F M F M F Iz x Xl M F M F M F IV 38 2 Coding with guide pins and guide sockets The guide pins and guide sockets actually fulfil two tasks 1 Improved guiding of the plug in process 2 Coding made possible by targeted insertion of the guide pieces Insertion is only possible with male female pairs sms Figure IV 38 4 Guide pin ligure IV 38 4 Guide socket e r d eus Figure IV 38 6 Coding with guide pins and guide sockets IV 73 IV Installation Instructions qi HARTING Coding for housing with a contact insert sizes 10 A 16 A and 6 B to 24 B I 0 m D XI JL v Go G om OO oO OQ L M F M F M F M F M F M F Vl Vl Iz x XI X gt o a o 0 M F M F M F M F M F M F Xn x DN zw C o 0 a B a M F M F M F M E Guide pin M Male pin insert O Guide socket F Female insert Retaining screw Coding for housing with two contact inserts sizes 32 A and 32 B 48 B I 1 n D o Za j a D o ew rj a oO e it O u j m 2 i C C a ijt O a iji o M F M F M F M F Y a ND Xn u l a j o Lok o rr s It e D ortos M F M F M F M F x x ZI XII aa WR LI E Li amp H 0 gt A 0 og ji gt EB M F M F M F M F zm zm Kei GE KE O Oo amp i e a i s Oo 1 O a j 6 H F M F M F Note According to DIN 43652 connectors must be constructed so
35. compatible if it has sufficient inter ference immunity and has tolerable emissions or sensitivity In order to meet these requirements HARTING delivers hood and housing with excellent EMC characteristics Such hood and housing includes the Han HPR and Han EMC B series Figure Ill 3 1 Figure Ill 3 2 Han HPR hood and housing Han EMC B hood and housing The EMC requirements for an interface stipulate that the rated shielding attenuation potential or the degree of interference immunity must be high enough so that the electromagnetic field surrounding the connector cannot interfere with the signal transmission inside the connector The permeability of electromagnetic radiation outwards must also be minimized so that the connector does not interfere with surrounding devices or components The following graph shows the shielding attenuation behaviour for HARTING s InduCom connectors as a func tion of the frequency Figure lll 3 3 Han EMC B housing III 27 III Connectivity Products This EMC hood and housing has a distinctive labyrinth structure and a large surface contact between the bulkhead mounting housing and the hood both of these factors help to deliver the high shield attenuation values for the hood Figure lll 3 4 Labyrinth structure of the Han HPR series Hood Han EMC B with conductive surface O ring seal Adapter Han EMC metal frame with conductive surface O ring seal Hood bulkh
36. for metric cable entries metal eee oe N x Table UL 8 12 Reducers for metric cable entries metal Part number EE U III 83 Ill Connectivity Products SEA HARTING Table Ill 8 13 Covers for Han HPR bottom housing section Transport protective For bulkhead mount cover HPR ing and surface mounting housings IP 20 protection To snap on 09 40 003 5406 Size HPR 3A 09 40 006 5406 Size HPR 6B 09 40 010 5406 Size HPR 10 B 09 40 016 5406 Size HPR 16 B 09 40 024 5406 Size HPR 24 B Covers HPR For bulkhead mount ing and surface mounting housings IP 68 protection Screw lock 09 40 006 5411 Size HPR 6B 09 40 010 5411 Size HPR 10 B 09 40 016 5411 Size HPR 16 B 09 40 024 5411 Size HPR 24 B 09 40 048 5401 Size HPR 48 B III 84 Ill Connectivity Products III 9 Spare parts HARTING The following table lists information on screws PE retaining and interlock screws and seals flange profile and O ring seals for Han B housings and HPR housings Additional information is included about interlock mecha nisms that are also available as spare parts Table Ill 9 1 Screws interlock levers seals PE screw for Han A Han 15 25 D 09 20 000 9919 for Han E etc 09 33 000 9925 PE screw for Han Com Han HsB 09 33 000 9926 Retaining screw 09 16 000 9903 Contact screw 09 30 000 9997 Han 3 A retaining screw 09 20 000 9995 Han 3 A retaining screw 09 20 000 9918
37. in place Insert the wire into the terminal 2 Close the tool until the RATCHET RELEASES 3 Remove the crimped terminal 4 ATTENTION To release the ratchet mechanism push the trigger in the direc tion indicated by the arrow 5 HOW TO ADJUST It is sometimes necessary to adjust the crimp force 1 2 3 Remove the cover washer Note the setting wheel position the remove it Adjust the eccentric axle with a screw driver Turn the axle coun terclockwise to tighten the preload Place the setting wheel so the pin in the handle locks die setting wheel Replace the cover washer Check preload against factory specification MAINTENANCE It is recommended that each operator of the tool be made aware of and responsible for following these maintenance steps Remove dust moisture and other contaminants with a clean brush or a soft lint free cloth Do NOT use objects that could damage the tool Make certain all pins pivot pionts and bearing surfaces are pro tected with a THIN cost of any good SAE No 20 motor oil Do NOT oil excessively When the tool is not in use keep the handles closed to prevent objects from becoming lodged in the crimping dies and store the tool in a clean dry area IV 32 IV Installation Instructions eg HARTING IV 16 Crimping tool 09 99 000 0374 The crimping tool 09 99 000 0374 can be used to process wire end ferrules with round and trapezoidal shaped cross
38. inserts from the Han D series except for Han 7 D and standard housings sized 10 A 16 A 16 B and 24 B DIN EN 60 529 Degrees of protection provided by enclosures IP code e NFF 61 030 On request VII 2 VII Selected Standards Relevant to Railway Applications T nq V lt csvyO y gt Ov 7W A II HARTING Connection method DIN IEC 60 352 2 Solder free connections Part 2 Crimp connec tions general requirements testing methods and usage notes crimp wire connection DIN IEC 60352 3 Solder free electrical connections Part 3 Sol der free accessible insulation displacement con nections DIN EN 60 999 Connection material torque screw connection DIN 46 235 Cable lugs for compression connections cover plate type for copper conductors VII 1 2 The railway standard EN 50155 It is common to ask if a component is suitable for railway use Technically however the question is whether the component fulfils the requirements of EN 50155 Although this is a European standard there are jobs and requests for bids outside of Europe which also call for compliance with EN 50155 EN 50155 is valid for electronic facilities on railway vehicles This is a type of umbrella standard which describes testing processes including procedures to test for electromagnetic compatibility EMC environmental factors cold heat and humidity degrees of protection shock and vibration Regarding wire connection me
39. module adaptor and lock it with an audible click IV 84 IV Installation Instructions d HARTING 9 Put on the upper shielding shell and press it over the cable screen Af terwards put on the lower shielding shell and lock it with the upper shell with an audible click 10 IP 20 Data Push the housing over the assembled data module until is snaps in with an audible click Han 3 A Place the data module in the housing adapter and insert into the plug housing Secure the housing adapter using the sealing screw ee RJ Industrial RJ 45 IP 20 RL gi C db 11 IP 20 Data Tighten the cable gland Push Pull Tighten the cable gland We recommend using an open ring spanner wrench with a spanner width of SW 19 Han 3 A Tighten the cable gland Do not pull on the cable in the pro cess We recommend using an open ring spanner wrench with a spanner width of SW 22 IV 85 IV Installation Instructions zazan HARTING Notes IV 86 V Ethernet Networking Systems gi HARTING Chapter V Ethernet Networking Systems Table of Contents V 1 Network systems 2 V 2 Ethernet Switches for transportation 3 V 2 1 The Ha VIS eCon Unmanaged switch 3 V 2 2 The Ha VIS sCon configurable switch 3 V 2 3
40. nuts on the back of the tool 5 Identify the following parts A Indener F Locator B Selector Knob G LockingScrew C Pointer Ip Ratchet Release Pin D Selector Plate K Elastic Stop Nu _ E Lateh L J Adjustment Window LOCATORS Three different locators can be selected for the tool Han C contacts 09 99 000 0308 Han D contacts 09 99 000 0311 Han E contacts 09 99 000 0310 IV 28 IV Installation Instructions HARTING Locators have to be corresponding to the type of crimp contact CAUTION Do not open tool forcibly MOUNTING OF LOCATOR Install desired locator F Push latch E into closed position and tighten locking screws Check that right locator F for desired contact is chosen To change or mount locator loosen locking screw G Pull latch E into open SELECT CRIMPING DEPTH 1 2 Open and close tool several times To adjust crimp depth bring tool in open position Set the pointer C on the corresponding wire gauge diameter D It is necessary to check the setting by using the correct gauge pin There fore close the tool and set gauge pin into the indenter opening A If this is not possible open tool again Turn selector knob B to open or close the indenter a little more Close tool again and insert gauge pin into indenter opening A If necessary repeat point 4
41. out forces and temperature characteristics We can authorize the configuration when it is proper After our authorization installation instructions customized to your requirements and application can then be created Figure IV 8 1 Figure IV 8 2 Double connection for the Han Double connection for the Han HC Modular 650 contacts with two HC Modular 350 contacts with two cables each with a 35 mm wire cables each with a 25 mm wire cross section cross section IV 22 IV Installation Instructions E HARTING IV 9 Han HC Modular 350 and 650 high current contacts with screw connection In addition to the high current contacts which use the axial screw connection method it is also possible to connect cable lugs to high current contacts The cable lugs can be fitted to cables with 120 mm wire cross sections for the HC 350 or to cables with 70 to 240 mm wire cross sections for the HC 650 On the connection side they consist of a flat washer a spring washer and a hex screw M10 for the HC 350 and M12 for the HC 650 During the installation of the cable lug be sure that the components that are placed over the hex screw are placed on in the proper order Cable lug Flat washer Spring washer You must also apply counter pressure to the counter support as shown in Figure IV 9 1 of the contact using a spanner wrench Han HC Modu lar 350 SW17 Han HC Modular 650 SW24 This will stop the spread of the torqu
42. require ments Han Modular is the logical next step for the Han Com series The key ad vantage of the Han Modular is that customers can combine the modules to suit their needs and thus design their own customized connector This series can be used for signal transmissions i e in bus cables or for transmitting rated currents of up to 200 A The following figure shows the assembly process for the Han Modular The Han Modular system is designed to be installed in housings from the Han B Han Eco Han Yellock Han EMC B Han M and Han HPR series The tall design should be used whenever possible with the hood and surface mounting housings with the exception of the Han HPR Figure Ill 4 1 Han Modular I 31 III Connectivity Products HARTING III 4 2 Han HC Modular This series features high current contacts for rated currents from 250 to 650 A Conductors are connected using the axial screw method or with crimp con tacts A mounting frame must first be inserted before installing the contacts in the housing The frames are designed only to be used in the Han HPR and Han 48 M housing series Table IIl 4 1 Han industrial connector an overview of contact inserts and modules Contact insert Area of use Product photo module contact accessory Hinged frame for 2 3 4 Accessories and 6 modules as For modular use Retention for hinged Accessories frame Helps during assembly by p
43. sCon configurable switch 3 V 2 3 The Ha VIS mCon managed switch 4 EE asas dra D EUR L EU DIN SPERA PUEDE aa mm 7 walan ee 12 Customer Specific Solutions 2 Wagon to wagon cable assembly 2 SPEC lal MOUSIN GS uu sus neyene s yan keke Kak a lek DU ew lae e Keke K n 5 MVB WTB Service BOX 6 Junction and distributor box 7 Customized metal panel processing and electronic fittings 8 Interior Cabling for rail vehicles 9 Connector sets and accessories 10 Customized printed circuit boards 11 Selected Standards Relevant to Railway Applications 2 MILI Connector standards E 2 VII 1 2 The railway standard EN 50155 3 VII 1 3 Additional standards 4 VII 1 4 Flammability directives 7 Foreword 4 HARTING Foreword The railway industry and the HARTI
44. sections for 10 mm cross sections The wire end ferrules are processed as round crimps and are pressed down very hard Because of their small size the ferrules processed as round crimps can be used in even the smallest of housing receptacles Interlock The tool comes with a locking mechanism which ensures that all crimp con tacts have a uniform crimping quality e t prevents the tool from closing before the crimping jaws are opened t prevents the tool from being opened prematurely during the crimping process Premature unlock mechanism The tool can be unlocked prematurely by using the ratchet lever The lever is spring loaded between the hand grips Press the grips gently together in or der to take the load off the tool Then use a screwdriver to move the ratchet lever against the spring tension to the right This can be done to prevent the crimp profile from being damaged when the contact is not seated properly in the crimp profile Do not open or close the tool using excessive force Be sure to oil the movable parts regularly The crimping process Insert the wire end ferrule in the crimp profile that is appropriate for that size e Secure the ferrule between the slightly closed crimping jaws nsert the cable correctly stripped of insulation into the contact Crimp until the tool opens again Remove the wire end ferrule it is crimped and ready IV 33 IV Installation Instructions 9
45. series have an O ring seal on the bulkhead mounting side When the housing is properly installed with this seal IP 68 or IP 69 K protection can be achieved These housings have through holes for the M retaining screws located within the sealed area of the housing refer to Figure IV 31 1 This allows you to use through holes or continuous threads on the mounting surface Such holes and threads will not affect the sealing If you installing on metal panel walls then a proper mounting frame should be used just as with the Han B standard housings to ensure the stability of the mount and the proper housing seal Mounting frames with M threads are available for the HPR housings Just as with the standard housings the instal lation is carried out from the rear side on the mounting wall Retaining hole in O ring seal Figure IV 31 1 Han HPR bulkhead mounting housing with O ring seal IV 56 IV Installation Instructions E HARTING IV 32 Han HPR housing size 3 A Two versions of bulkhead mounting housings are available for this size e Straight bulkhead mounting housing e Angled bulkhead mounting housing The straight bulkhead mounting housing from the 3A series just like the HPR bulkhead mounting housings in sizes HPR 6 B 10 B 16 B and 24 B should be fitted with an O ring seal on the bulkhead mounting side Here too the through holes for the M4 retaining screws are located within the sealed area This hous
46. that it is possible to plug them in at a lengthwise skew of 5 degrees and a perpen dicular skew of 2 degrees The use of guide pins and guide sockets pre vents a larger skew or slant from taking place during the plugging Guide pins and guide sockets are required for all high pole connectors Please contact us if you require other coding options than those described here IV 74 IV Installation Instructions E HARTING IV 39 Locking panel for locking lever HARTING offers a locking panel refer to Figure IV 39 1 that prevents the lever interlock mechanism on the connector from being opened or tampered with This locking panel can be used with bulkhead mounting housings of sizes 10 B 16 B and 24 B with two locking levers cross lever Two versions are available 09 30 000 9986 for the Han Easy Lock locking lever 09 30 000 9987 for the metal lever Alockingpanelforbulkhead mountinghousingsin 6 B 24 Bwith 1 Han Easy Lock locking lever lengthwise lever is available on request from HARTING S Figure IV 39 1 CM Locking panel The locking panel is designed so that once it is installed the interlock lever cannot be opened by hand The locking panel can only be installed when the connecter is interlocked A cord attached to the housing flange is used to ensure that the locking panel stays in place refer to the following images 1 The panel is inserted from the top 2 The panel is pushed through until the me
47. the Han Industrial Han C 1 5 10 0 mm Connectors Catalogue AWG 16 AWG 8 III 68 Ill Connectivity Products e E HARTING Product photo Crimping tool Crimping tool For individual contacts 09 99 000 0620 BC and FC Crimp die set For individual contacts 09 99 000 0621 BC FC1 09 99 000 0622 FC2 09 99 000 0623 FC3 Locator For individual contacts 09 99 000 0630 BC 09 99 000 0631 FC Service case Crimp tool with 09 99 000 0632 5 crimp die sets and screwdriver for changing the inserts without contents Crimping tool for reel packaged contacts DIN 41 612 for reel with 500 contacts BC 09 99 000 0248 for reel with 500 contacts 09 99 000 0247 FC1 09 99 000 0119 FOZ 09 99 000 0120 FC3 Crimping tool for for contacts FC1 individual contacts FC2 and FC3 Servicing tool A locator is 09 99 000 0191 included in the delivery Manual crimping tool For crimp flange 61 03 600 0020 and crimp sleeve III 69 III Connectivity Products SSSA HARTING Table lll 8 2 Tool inserts Product photo For manual crimping tools 09 99 000 0501 SW mm 5 0 61030000098 60 61030000104 90 6103 000 0105 Tool inserts 1 SW spanner width III 70 Ill Connectivity Products S SOS HARTING Table Ill 8 3 Removal disassembly tools Product photo Removal disassembly tools Han D Opens the contact cavity 09 99 000 0012 on the plug side Pulls o
48. to interlock the male and female sides together A strain relief clip is mounted to the hinged frame of the connector in order to support the cable Figure ll 5 1 The model B80D tram vehicle for Bursa Turkey NS Figure ll 5 2 Figure ll 5 3 Driver controls Connector with knurled screw before final installation for interlock and strain relief clip Il 6 Il Application Examples 2 SSS HARTING II 6 Rotary encoder Another typical application is to provide a pluggable solution for rotary en coders and sensors for the purpose of monitoring storage temperatures An example shown here is from Bombardier Transportation Bombardier has manufactured multiple Blue Tiger diesel electric locomotives for use in Germany and Europe D The following illustrations show the connector Since the connection is in stalled in a location that is exposed to extreme weather conditions it is de signed to use the Han HPR series of housings This solution allows for parts to be quickly swapped out with minimal effort during servicing RU KZ ri hai ge e LA a Li Figure Il 6 1 Figure Il 6 2 The Blue Tiger diesel locomotive Connector with connecting cable to the rotary encoder II Il Application Examples ee 555555555 SS SS HARTING Il 7 Data communication Video monitoring is an example of data communication within a railway vehi cle In this application the video monitoring is Ether
49. used during product development These tests are subject not only to electrical standards such as DIN EN 61984 but also to the appropriate railway standards such as EN 50151 and DIN EN 61373 A comprehensive product line application expertise and excellent quality these are the factors that have brought HARTING success in the railway sector These are also the strengths that we will use to support our future collaboration Il Application Examples S SO HARTING Chapter Il Application Examples Table of Contents Me Wee 2 Il 2 Integrating connectors into the design phase of railway vehicles 3 I oo devicti 4 Il 4 Connector for wagon couplings 5 Il 5 Connectors for control data and bus data in the driver s console 6 le 6 Rotary een TRU 7 ll 4 Data COMMMUNICATION i yyy u veut anan kele al n He k bene eed xak Pr 8 ll 8 Stationary rail equipment 9 Il 9 Connectors for use in interiors of railway vehicles 10 Il 10 Sub floor container Em T m 11 Il 11 Connectors in the electrical cabinet 12 Il 12 Controlling pantographs 13 Il 13 Connectors used in the coupling area of railway vehicles 15 Il 14 Monitoring unit for the brake s
50. z 18N 0 25 24 gt z 32 N 0 50 20 gt 60N 0 75 18 gt 85N 1 50 16 2150 N Locator Conductor cross section 0 14 0 25 mm awe 25 24 FCl 0 75 1 50 mm awe 18 15 FC3 Only limited conductor cross sections for FC contacts can be used Modifications due to quality improvements advancements or manufacturing requirements we reserve ourselves IV 42 IV Installation Instructions Ce HARTING Ratchet The crimping tool is fitted with a safety ratchet to ensure that all contacts are crimped to a constant quality e It prevents the jaws from being re opened until they have been completely closed Early release It is possible to perform an early release of the safety ratchet if a crimp is faulty Relieve the pressure from the jaws by slight pressure on the handles and move the release lever see diagram in the direction of the crimping tool head Damage to the crimping die will thus be prevented if the contact does not lie correctly in the die profile DO NOT USE EXCESSIVE FORCE TO OPEN OR SHUT THE TOOL LUBRICATE ALL MOVING PARTS WEEKLY Fixing the locator The locator supplied must be fixed to the head of the tool see fig below Tide the screw carefully Locator Gauge specifications 0 14 0 25 mm AWG 26 24 FC1 0 75 1 50 mm awe 18 16 FC3 0 25 0 56 mm AWG 24 20 FC2 Crimp height adjustment Release IV 43 IV Installation Instructions a lt lt lt lt lt t lt t
51. 100 A module 2 pole 1000 V Axial screw connection Crimp connection Han K 3 0 3 pole 1150 2000 V Axial screw connection Han 200 A module 1 pole 1000 V Axial screw connection Crimp connection Insulating base male female for holding the crimp contacts Han TC250 1 pole 2000 V Crimp connection Han HC Modular 350 1 pole 2000 V Axial screw connection Crimp connection Han HC Modular 650 1 pole 4000 V Axial screw connection Crimp connection III 37 uz Product photo Transmission Transmission of high power Transmission of high power Transmission of high power III Connectivity Products a n HARTING Table Ill 4 2 Overview of contacts and high current contacts Product Features Produktfoto D Sub contacts Rated current 5 A Cross section 0 08 0 75 mm Surface gold plated Special contacts for D Impedances 50 and 75 O Sub Mixed Frequency up to 2 GHz Coax contacts Solder crimp connection or Crimp crimp connection surface gold plated Special contacts for Rated current 2A D Sub Mixed high Operating voltage up to 3 kV voltage contact for cable Surface gold plated applications Wire cross section 0 25 0 56 mm Special contacts for D Rated current up to 40A Sub Mixed high voltage depending on contact for cable usage contact Surface gold plated Wire cross section 0 52 10 0 mm DIN 41 612 contacts FC Rated cur
52. 2 101 standards Order numbers 2103241 1300 2300 Male female 3 pole B coded Profibus version 2103281 1405 2405 Male female 4 pole D coded AWG 24 22 2103 282 1405 2405 Male female 4 pole D coded AWG 22 20 2103 221 1405 2405 Male female 4 pole A coded Figure IV 41 1 HARAX M12 L shielded Table IV 41 1 Technical specifications LL MIZL M12 L Ethernet M12 L Profibus AWG 24 22 AWG 24 20 AWG 22 Coding JA 3 D LD B View mating side male HARAX M12 L shielded 3 pole 4 pole 4 pole PROFIBUS Ethernet Mounting 1 Strip cable 2 Assemble HARAX elements twist screening braid and push it into the sealing slot 3 Slide ring over the sealing cut off cable ends and the screening braid 4 Screw the connector 8 Nut D Strain relief O Insert Note For reconnection cut off the used cable ends and repeat steps 1 to 4 IV 78 IV Installation Instructions M ee Ff ol HARTING IV 42 Han 3 A RJ 45 4 pole Order numbers IP 20 09 45 151 1100 IP 65 metal 09 45 115 1100 Standard 09 45 115 1102 Han M version Technical specifications for IP 20 Technical specifications for IP 65 Connector type RJ 45 connector acc Connector type Han 3A connector to IEC 60 603 7 RJ 45 acc to wv IEC 61 076 3 106 Number of contacts 4 S ISTE Transmission Category 5 Class D Number of contacts 4 performance up to 100 MHZ acc to ME ISO IEC 11801 2002
53. 240 mm 27 IV 13 Buchanan four point crimping tool 09 99 000 0001 28 IV 14 Hand crimping tool 09 99 000 0110 31 IV 15 Crimping tool 09 99 000 0303 E 32 Velo Crimping tool 09 99 000 0378 eege ee 33 IV 17 Crimping tool 09 99 000 0377 34 IV 18 Crimping tool for coaxial contacts 09 99 000 0503 35 IV 19 Crimping tools for D Sub contacts 09 99 000 0501 36 IV 20 Crimping tool for individual DIN contacts BC and FC 09 99 000 0620 38 IV 21 Crimping tool 09 99 000 0248 40 IV 22 Hand crimping tool 09 99 000 0191 42 IV 1 IV Installation Instructions 9 IV 23 IV 24 IV 25 IV 26 IV 27 IV 28 IV 29 IV 30 IV 31 IV 32 IV 33 IV 34 IV 35 IV 36 IV 37 IV 38 IV 39 IV 40 IV 41 IV 42 IV 43 HARTING Installing the crimp flange and crimp sleeve ele Rue WU eene EE 44 Han Quintax E 45 K IER E et E 46 Han D COIN saunders 47 Hal ECOU EEN 48 Hari GigaBit Module M l keke kek k k 49 Han 46 EE Multiplier uneegnen 52 Assembly notes for the Han B housing 54 Han HPR housing sizes 6 B 24 B
54. 3 O ring seal Figure IV 34 1 Han 3 A with O Ring seal When installing these inserts in housing from the Han A Han M or Han EMC se ries the O ring remains on the contact inserts in order to ensure a proper seal on the connector If these contact inserts are installed in size 3 A Han HPR housings be sure to always remove the O ring seal Refer to Figure IV 33 1 You must re move the O ring because the HPR housing comes with its own O ring seal In order to achieve IP 68 protection you should use the M3 sealed screw instead of the M3 retaining screw that is included with the delivery The sealed screw is included in the delivery of the Han 3 HPR housing It can also be ordered separately under order number 09 20 000 9918 If during the installation you determine that the upper and lower sections of the plug in connector do not interlock properly make sure that the O ring seal has already been removed from the male pin insert IV 59 IV Installation Instructions py IV 35 Han Brid contact inserts Figure IV 35 1 Han 3 A with Han Brid HARTING also offers contact inserts in size 3 A that have male pin inserts with no O ring seal The contact inserts from the Han Brid series fall under this category The Han Brid Quintax 3 A insert can be used with this product series in railway applications In order to ensure that the connector is sealed properly be sure select a hood variant with an adhesive atta
55. 3 Overview of Housing DIN 41 612 IEC 60 603 2 Shell housing D20 Plastic Shell housing D20 metal for shapes F H and MH Shell housing D20 metal HF With nickel plated surface Robust plastic housing with good flammability characteristics Robust full metal housing with good shielding characteristics Robust full metal housing with good shielding characteristics and shield connection Interior of railway wagons Mechanical protection for signal lines that do not have special shielding requirements A metallic variant is also available Interior of railway wagons Electrical cabinets distributor boxes contact for analogue and digital signals in interface applications Interior of railway wagons Electrical cabinets distributor boxes contact for analogue and digital signals in interface applications The above housings are used for electrical installation on trains and in sta tionary applications III 26 Ill Connectivity Products Fu HARTING Ill 3 Hoods and Housings for EMC requirements Many interfaces have demanding EMC requirements for their connectors What does EMC mean Electro Magnetic Compatibility refers to the ability of electrical equipment to function satisfactorily in its electromagnetic en vironment without introducing intolerable electromagnetic disturbances to anything in that environment DIN VDE 0870 Electrical equipment is considered to be
56. 4 B One PE screw Figure IV 36 4 Grip panel Product article number 09 00 024 5611 Description Screw adapter top section with grip panel 09 00 000 5601 and 09 00 024 5601 Included in delivery Two screw adapters top section Two knurled screws One grip panel size 24 B One PE combi screw SOC Fd y 2 LE Figure IV 36 5 Contact insert only an example Male and female possible IV 63 IV Installation Instructions 9 HARTING IV 36 2 Bottom section Product article number 09 00 000 5603 Description Included in delivery Remarks Through holes with M5 thread for holding the M4 retaining screws M4 retaining screws self Screw adapter bulkhead mounting side bottom section Two screw adapters Two M4 self captive retaining screws Four M3 retaining screws for contact insert This adapter is easier to install when compared to the screw adapter version 09 00 000 5602 One of the advantages is the type of retention used Both of the M4 retaining screws included in the delivery refer to Figure IV 36 6 are used to mount to the metal panel wall These screws are self captive and can be re used several times Thus the adapter can remain on site even when the contact insert has been re moved This is not possible with version 09 00 000 5602 Another advantage is that a rectangular cut out is sufficient for installation refer to Figure IV 36 7 and so it is not necessary to cut out any spec
57. 43N OLSSNIG OA f61 6 970 e euoq eo jod S ILS 0 X NYH 019144N OLSSNIG OA 610 6 EZIO jereuoqueo jod J 83 vZ UeH 019144N OLSSNIG OA 610 l09 1 ER 480 0 e1 uoq eo jod o nq 3 pz ueH 019144N OLSSNIG OA v 1n mi osz LILO Jereuoqueo jod S vz UeH 019144N OISSNIG OA 610 ri ER 40 0 jayeuoqieofjod 2 053 yz ueH 019144N 016SNIG OA 610 ent 6 88 Logg e1euoqueofjod 4 S3 9l UeH 019144N OLSSNIG OA 610 ur 6 90 0 ejeuoqueofqod o nq 3 9 ueH 90 8000 80070 900 8700 vv00 640 0 ZOO FU U EENG 980 0 840 0 ve00 S600 O oO VD O y oa AN OLSSNIG OA v 3n en oez y80 0 suooeuod W S3 9 ueH 019144N OISSNIG ten ent 6 88 019144N OISSNIG OA 610 6870 osz oa AN OLSSNIG OA v 3n 0980 sz oa AN OLSSNIG OA 610 6990 osz oa AN OLSSNIG OA 610 sigo Tee oa AN OLSSNIG OA 610 8690 osz 3 680 0 e1euoqeofjod 9 S 3 9 UH 0 jayeuoqieofjod 4 83 0 ueH opp leuoqueo lod 9 nq 3 01 ueH 90 0 fejeuoqueojod IN S3 01 ueH 670 0 leuoqueo lod 2 093 OL ueH 460 0 leuoqueo lod J 83 ut UNI Sx W 83 i uonJod ajqewwel uonJo Lou spyepue1g aug SA ns Puls BE IEUSa1EN uondiJosep 140ug peo oil EUJ9U Meda Jo 1ug19M 8 VII Selected Standards Relevant to Railway Applications LGZZ ZLO 8 60 LS9Z ZLO 8 60 LELE 00 8 60 1292 00 8 60 LOLE 800 9 60 LOOE 800 9 60 9174
58. 5 Il 14 Monitoring unit for the brake system 17 ll 15 List of references 18 III 1 IH TOQ NC UI OF ote c r n sen d an lk B 3 III 2 Hoods and housings overview 4 Ill 2 1 Overview of Han hoods and housings and contact inserts 4 Ill 2 2 Installation location of the hoods and housings 6 Ill 2 2 1 Overview of housings and locations for industrial connectors 6 III 2 2 2 Overview of products and locations for interface DIN connectors 8 Ill 2 3 Han HPR housing size 3 A long version 10 Ill 2 4 Han B hood with M50 cable entry 11 llI 2 5 Han Easy Hood eker kek Rare kK Eer 11 Ill 2 6 Han HPR and Han M hood and housing 12 Ill 2 6 1 Han 24 HPR enlarged hood and housing 13 Ill 2 6 2 Han 48 HPR hood and housing 14 Ill 2 6 3 Han 48 M hood and housing 16 Table of Contents III 3 III 4 III 5 III 6 III 7 III 8 III 9 HARTING III 2 7 Han Eco hood and housing ssessssc
59. AU 91 9 YOZ XV 4 POWZ UeH uondiosep 110uS LOOE 900 YL 60 9122 S00 YL 60 9197 00 Pl 60 eI 6t 700 FL 60 cL Gt 700 FL 60 LOS 700 vl 60 LLLE 100 FL 60 LLOE LOO YL 60 COLE 00 FL 60 LOLE 00 pl 60 OOE 00 FL 60 LOOE 00 tl 60 0Z 00 Pl 60 LOZZ 00 PL 60 2092 00 YL 60 L09c 00 PL 60 LOLE 00 YL 60 LOOE 00 pl 60 ISLE 00 VI 60 LGOE 00 YL 60 GZZ 00 Pl 60 LGZZ 00 v 60 LvZZ 00 Pl 60 Jequinu yed VII 11 HARTING VII Selected Standards Relevant to Railway Applications 8H pe Zeg 8000 800 0 piuue jod 9 I1S GZ NYH 160 Z00 1Z 60 L019133N OLSSNIG OA 610 7 ez zoo 4800 jareuoqieofjod O ng qd 801 NYH LOLE 801 91 60 L01914N OLSSNI OA 2610 DO ez vaoo 6900 jareuoqueodjod 2 11S QQ 801 NYH 100 801 91 60 LOL9L44N OLGSNIG OA 610 SN 6g2 S00 4900 jneuoqieofjod 0 f18 Qd ZZ NYH LOLE 220 91 60 LOL9L44N OLGSNIQ OA 610 0860 ez gg 9900 jneuoqieoApod 0 s dQ ZZ NYH 100 ZZ0 91 60 019144N OLSSNIC OA Fein 80670 eez sem gso o jareuoqieohjod 2 f8 QQZ NYH LOLE ZYO 91 60 LOL9L44N OLSSNIG OA Fein LIZO ez oeoo svoo jeuoqieofjod 2 11S QQZ NYH 100 ZYO 91 60 p puestos 0 LOL9144N OLSSNIG OA 610 699 0 ert 8200 evo o e18uoqJeo jod 0 4 QQfZ NYH LOLE vZO 91 60 L019143N OLSSNIC OA Fein 8690 sz een opo o jareucqieofjod Us 007 NYH 100 720 91 60 019144N OLSSNIG OA 610 dd 6 ez
60. Axial Screw connection hlle eS Mounting frame for Han housing Coding elem ntis E Accessories Clamps and strain relief frame Han EE Multiplier KK A kk hiEi keke Cable SIG a w w _ _aXrbbbmmm o HARTING Ill Connectivity Products SS ee OO HARTING Ill 1 Introduction This chapter introduces the products that are currently being used for electri cal connections in the railway industry The requirements of this industry are taken into consideration at the earliest design stages The following criteria should be considered when selecting a product The place of use and the environmental surroundings for the connector a criterion for selecting the hood and or housing Currents and voltages a criterion for selecting the contact inserts and contacts Wire construction a criterion for selecting the type of con nection EMC and shielding a criterion for selecting the housing and cable gland The modular design of HARTING products allows almost all contact inserts to be combined with all types of hoods and housings Thus it is also possible to put together inappropriate combinations Contact us if you are unsure of the best combination The following pages describe the HARTING products that are most often used in railway applications Additional information can be found in the catalogues Industrial Connectors Han Device Connectivity and Ethern
61. Com series to data and signal cables HARTING s Han E Han EE and Han Modular series HARTING also provides the additional service of offering pre assembled and tested connector inserts The customer benefits from the significantly short er installation time in the electrical cabinets The following illustrations show an electrical cabinet from the Desiro train DB series 642 built by SIEMENS Mobility Figure ll 11 1 The Desiro DBAG diesel train from the 642 series Figure ll 11 2 Figure ll 11 3 HARTING connectors used as the The Han Com Han E Han EE interface to the electrical cabinet and Han Modular series Il 12 Il Application Examples 2 HARTING Il 12 Controlling pantographs The firm Stemmann Technik manufactures pantographs for overhead wire systems Pluggable connectors are used for the pantographs and for the de vices that control the pantographs so that less time is required during instal lation and servicing A 24 pole Han E contact insert in a Han B housing is used to provide a pluggable solution for the controlling device Since the connector is not located outside on the roof but within the vehicle the Han B housing is sufficient for this application Figure ll 12 1 Figure ll 12 2 Rooftop pantograph DSA 200 Detailed view of the Han 24E connector from the firm Stemman Technik that is built into the controlling devi
62. EE Han Modular or Han Com can also be considered for use Note here that HARTING delivers the connectors for the junction of the ve hicle coupling units Figure ll 13 1 Opened front hatch on an ICES train The coupling unit is easy to see The contacts for the electrical connections between the coupling units are covered The control unit refer to Figure Il 13 2 for the front hatch not visible here is located directly behind the coupling unit II 15 Il Application Examples ns HARTING Figure ll 13 2 Figure Il 13 3 Control unit for controlling the front Rear view of a coupling unit hatches for example on the ICE 3 shown at an exhibit at In Shown here for the Kassel city tram noTrans line using HARTING connectors from the Han Modular series Quintax DD module for data cables Han K 4 0 for transmission of high currents up to 80 A and Han EE for transmitting mid range currents up to 16 A The contact inserts are installed in HPR housings since the control unit is located directly behind the vehicle coupling Figure ll 13 4 Han Modular contact inserts with Quintax EE module and Han 46 EE mounted in the Han M hood size 48 B II 16 Il Application Examples SO HARTING Il 14 Monitoring unit for the brake system The example here uses DIN 41612 series connectors within the interior of a railway vehicle Figure Il 14 3 shows a DIN metal housing mounted on a pus
63. Han HPR interlock screw 09 40 000 9932 Han HPR interlock screw 09 40 000 9929 For all Han monobloc contact inserts Without sealing ring With seal for IP 65 protection M For HPR hood housing Sizes 6 B 10 B 16 B and 24 B with screw interlock 09 40 0xx 0x1x 19 40 Oxx Ox1x M3 For HPR hood Size 3A with screw interlock 19 40 x03 041x III 85 III Connectivity Products po HARTING Product pe Locking lever features mme Han Easy Lock 1 lever locking system Sizes 09 00 000 5222 09 00 000 5228 09 00 000 5229 09 00 000 5230 09 00 000 5224 09 00 000 5225 Han Easy Lock 2 lever locking system Sizes 09 00 000 5221 10 B 16 B 24 B 09 00 000 5223 32A 09 00 000 5231 Han Easy Lock X 1 lever locking system 09 00 000 5401 09 00 000 5264 09 00 000 5288 Han Easy Lock X 2 lever locking system Sizes 09 00 000 5204 10 B 16 B 24 B Metal locking lever ek complete 09 00 000 5205 Size s Stainless steel 48 B Metal locking lever with Illustration is similar to the ratchet 09 00 000 5295 Size 09 00 000 5205 but with Stainless steel 48 B out the retaining material Interlock roll Size 09 30 000 9998 48 B two per housing Locking panel For Han B bulkhead for Han Easy Lock mounting housings sizes cross lever 10 B 16 B 24 B 09 30 000 9986 Locking panel for metal cross For Han B bulkhead mounting No illustration levers 09 30 000 9987 housings
64. Locking lever without ratchet on housing ratchet on housing III 16 Ill Connectivity Products OO HARTING IL3 7 Han Eco hood and housing Like the Han B series the new Han Eco hoods and housings are available in the sizes 6 B 10 B 16 B and 24 B This new housing series is made not from die cast aluminium like the Han B series but from glass fibre reinforced polyamide Han Eco was designed for modules in the Han Modular series In compari son to the Han B housing the new design allows space for an additional module in each of the four sizes Despite the increased modular density the installation dimensions are identical to the Han B series The high performance plastic used in the housing is extremely resistance to environmental influences The plastic also features excellent mechanical properties IP 65 protection in accordance with DIN EN 60 529 is ensured when the housing is mated and locked This new housing series can be used in protective insulated facilities and machines according to protection class Il It also meets the flammability classification for VO material according to UL 94 The Han Eco series is available with a straight or side cable entry The module frame and the cable gland are integrated into the hood so there is no need to order them separately The module frame is also integrated into the housing with the bulkhead mounting housing which reduces the number of article numbers required The asse
65. NG Technology Group have enjoyed a successful partnership marked by a long tradition of trust and cooperation HARTING has delivered connectors and rail accessories to the railway indus try for many years The expertise and data that we have gathered over these many years of cooperation has provided the foundation for many of our in novations This document is not a replacement for our catalogue instead it provides an overview for the use of HARTING products and solutions in railway vehicles and stationary rail applications We ve brought together the information that we think will make the user s job easier whether that job is in construction development or in production Not only installation instructions are included here you will also find descrip tions of the certifications regulations and directives that are relevant to the railway industry and with which HARTING products are naturally in compli ance This book is structured so that a variety of information relevant to specific in terest groups can be found quickly and simply Sample applications are used to provide the reader with an overview of the many uses for HARTING prod ucts A selection of products based on connection methods supplemented with the corresponding installation instructions is also included The prod ucts are organized and shown according to their applications whether for indoor or outdoor usage for data transfer or for carrying high currents We th
66. NG offers custom sets which include all com ponents necessary for creating an electrical connection The actual grouping of components is tailored to the corresponding project and is optimized for on site installation Customer specific labelling of packaging is also an op tion Such tailored sets provide a simplified ordering mechanism and elimi nate the risk of errors They also help to save time when using the products Figure VI 8 1 Packaging in sets for the Han connector Figure VI 8 2 Example of package sets for the System Box VI 10 VI Customer Specific Solutions VI 9 Customized printed circuit boards HARTING designs and manufactures circuit boards and backplanes for all customer specific applications including completely integrated systems Our wide range of services and deliverables also includes simulations solution analyses as well as a variety of signal and system tests We can profession ally process both individual and larger batch orders VI Figure VI 9 1 Example of a customized backplane VI 11 VI Customer Specific Solutions EE HARTING Notes VI 12 VII Selected Standards Relevant to Railway Applications Chapter VII Selected Standards Relevant to Railway Applications Table of Contents VII 1 Selected Standards Relevant to Railway Applications 2 VII 1 1 Connector standards 2 VII 1 2
67. Product i 2 article number i insulation 1070 END Tc100 a eae 09 11 000 6135 6235 16 14 ogi eee ee TC200 Han 70 A Crimp Module Han 200 A Crimp i TC250 250 35 35 76660 09 11000 6167 6267 650 240 5 2 09 11 000 6141 6241 350 50 28 22 ocr 50 5 2 ee tedir yas 9 IV 27 IV Installation Instructions 9 v oc HARTING IV 13 Buchanan four point crimping tool 09 99 000 0001 GENERAL 1 To provide a long life time and optimum performance this tool should be kept clean and handled with the same care as any other precision device 2 he tool provides continuously variable crimp depth adjustment to opti mum settings over a range of contact and wire combinations Its microm eter type adjusting knob B lets you select the precise crimp depth suited to your needs The tool can be used for Han D Han E and Han C con tacts and set crimp depth values varying from 0 14 4 0 mm2 For wire gauge 0 14 mm a special contact has to be used male 09 15 000 6107 6127 6307 female 09 15 000 6207 6227 6407 3 Open and close tool several times and observe precision cycle Press tool together before opening it Note that tool cannot be opened or closed without completing its cycle If for any reason the crimp cycle is to be aborted move the ratchet release pin to the left and the tool will release see depiction 4 Do not try to dismantle the tool Never lose or tighten the ELASTIC STOP
68. Pushing Performance HARTING User s Guide Transportation o HARTING All brand and product names are trademarks or registered trademarks of the owner concerned 1st Edition 2010 revised 09 10 HARTING Technology Group Espelkamp Author HARTING Technology Group Editor HARTING Technology Group Title Coradia Nordic Source ALSTOM Transport 2010 TOMA C Sasso Other figures Source HARTING Technology Group Subject to alterations without notice Printed on bleached cellulose 10096 free from chlorine and acid General Notes C e CCC HARTING General Notes It is the customer s responsibility to evaluate the suitability of the compo nents described herein and the applicability of the specified regulations for use in any special applications which have not been anticipated by HARTING HARTING reserves the right to make construction changes without prior no tice in response to manufacturing requirements improved quality advances in the design or for other miscellaneous reasons This information describes the components but should not be considered as a guarantee of certain prop erties Binding information will only be issued upon request by the appropri ate HARTING employee You will be assigned a contact partner in the contact information supplied by HARTING Additional information can be found in the catalogues Industrial Connectors Han Device Connectivity Ethernet Network Solutions Automation
69. The Ha VIS mCon managed switch 4 Ee 7 V 3 System cable quus matti Are y n a dukan uS k na CIAM vv kaya kA se na OR a RERUM dh a 12 V 1 V Ethernet Networking Systems 3 UUU HARTING V 1 Network systems Ethernet is a global standard which is being increasingly employed to handle train communication tasks Ethernet provides an excellent solution for ap plications requiring high speed data transmission such as video monitoring Modern rail vehicles offer many state of the art services including informa tion entertainment and internet access HARTING is your ideal partner be cause we can provide an Ethernet based network consisting of rail compliant components throughout the entire train We have designed reliable and complete solutions for wagon couplings and Ethernet switching to supple ment the standard M12 or RJA5 interfaces ES Figure V 1 1 Redundant Ethernet topology with HARTING managed switches Figure V 1 1 shows the logical design of an Ethernet network consisting of active components such as switches and passive components such as data cables and connectors This also includes the pluggable interfaces for the peripheral devices cameras and end terminals The following pages describe the components necessary for setting up a net work in rail vehicles active Ethernet components switches plug in connec tors for the wagon interior and for critical wa
70. Transmission Category 5 Class D EN 50 173 1 performance bis 100 MHZ acc to d I ISO IEC 11 801 2002 Transmission rate 10 100 Mbit s EN 50 173 1 shielding fully shielded Transmission rate 10 100 Mbit s 360 shielding contact Shielding fully shielded Mounting Field assembly 360 shielding contact Cable termination with piercing contacts Cable termination with piercing contacts Cable diameter Cable diameter stranded AWG 24 7 stranded AWG 24 7 AWG 22 7 AWG 22 7 solid AWG 23 1 solid AWG 23 1 AWG 22 1 AWG 22 1 Cable outer Cable outer diameter 6 1 mm 6 9 mm diameter 6 0 mm 9 0 mm Mating cycles culo PO Degree of protection IP 65 IP 67 Temperature Degree of protection IP 20 range 40 C bis 70 C EE M Housing material range 40 C bis 70 C Plastic version Polycarbonate Housing material Polycarbonate UL 94 VO black UL 94 VO Metal version Col Em Standard Zinc die cast powder a aA coating grey UL approval M version Zinc die cast powder E 102079 coating black IV 79 IV Installation Instructions a a HARTING Die Konfektionierung des Datenmoduls ist bei allen Varianten identisch Table IV 42 1 Contact assignments according to PROFINET Guideline Signal Function Adernfarbe Contact Nr RJ 45 TD Transmission e Orange PEE we o TD Iransmission SC eee ja Contact 6 Blue Contact 3 White RD Receiver SE m p am PUE se e ntt Rear view of data module Install
71. User Management Service Mode via Port 1 Quality of Service QoS IEEE 802 1p IEEE 802 10 Rev Port protocol based VLANs D5 0 2005 Redundancy Spanning Tree STP IEEE 802 1D 2004 Rapid Spanning Tree RSTP IEEE 802 1D 2004 V 5 Admin Guest and Service Level V Ethernet Networking Systems gai HARTING d Port Based Network Access Control Port Based Authentication with EAP 802 Is 2004 RADIUS Client RFC 2138 IP authorized managers Link Aggregation Security ISO IEC 8802 3 2005 E Link Aggregation LACP IEEE 802 3 2005 Edition Clause 43 IEEE 802 3ad Multicast IGMP Snooping v1 v2 v3 with sup RFC 1112 2236 port for querier 3376 DHCP Client RFC 2131 DHCP relay agent RFC 2131 DHCP Option 82 RFC 3046 Alarms via E mail SMTP and SNMP Traps signalling contact for low voltage detection or Link break Diagnostic Port diagnostic Port Mirroring Switch History MAC Address Table RMON 1 2 3 amp 9 groups RFC 2819 Management RFC 1155 1157 Password protected 1212 1213 1215 Web Management interface 2089 2578 3411 SNMP v1 v2c v3 agent amp 3412 3413 3414 MIB support 3415 3416 3417 3584 V 6 V Ethernet Networking Systems AT M HARTING V 2 4 Switches HARTING offers Ethernet Switches classified according to their function as derived from their corresponding area of use Table V 2 2 Overview of Ethernet Switches Functional classification
72. VIS sCon line feature a wide selection of con figuration options based on an unmanaged switch The Ha VIS sCon switches support per port configuration options and a variety of different network topologies Parallel redundant and ring redundant topologies can be imple mented The Ha VIS sCon ring redundant topology allows you to implement a ring to pology using HARTING s unmanaged sCon switches With the parallel redundancy two physical links are coupled together to form an active and passive link In the event of a link failure the connection is re established on the previously passive link within a few milliseconds The redundancy mechanisms provided by the HA VIS sCon switch give a network an increased level of security and reliability V 3 V Ethernet Networking Systems 3 _ _ M HARTING V 2 3 The Ha VIS mCon managed switch In addition to the standard functions already well known from the Ha VIS eCon and Ha VIS sCon series of switches the Ha VIS mCon switches feature additional management functions These functions help to implement a con vergent network that can be administered from one central location Ha VIS mCon switches support the use of VLAN for creating virtual network segments This allows you to better control the flow of communication and to avoid unnecessary network overload IGMP snooping ensures that multicast data packets only go to the intended recipients and are not broadcast and flooded throughout th
73. act 64 II 7 5 Axial screw connection 65 Overview of tools and accessories 66 III 8 1 Mounting frame for Han housing 73 III 8 2 Coding elements 74 Ill 8 3 Accessories Clamps and strain relief frame 76 Ill 8 4 Han EE Multiplier keke ek k 80 IS Ee Ee E 82 EE Eeer 85 Table of Contents 4 IV 1 IV 2 IV 3 IV 4 IV 5 IV 6 IV 7 IV 8 IV 9 IV 10 IV 11 IV 12 IV 13 IV 14 IV 15 IV 16 IV 17 IV 18 IV 19 IV 20 IV 2 1 IV 22 IV 23 IV 24 IV 25 IV 26 IV 27 IV 28 IV 29 IV 30 IV 31 IV 32 IV 33 IV 34 IV 35 HARTING Installation INSIMUGCTIONS LLL L Aaa k a AWA AWA NANAN 3 Contact inserts with axial screw wire connection 4 General installation information for contacts in the axial screw connection 9 Han HG Modular 350 22i uU u uy uu uu ab d ne K k er N ke baw lan 15 Han HC Modular EE 17 Installation instructions for the Han 24 HPR enlarged holder 19 Coding options for the Han HC Modular contacts 20 Doubled contacting with axial screw co
74. act The required coding for the HC contact can be made in 60 steps The figure below shows an example of a one pole variant These steps are also valid for the multi pole variants of the connector Step 5 Push the contact with the support frame into the hood Step 6 Tighten the four M3 retaining screws and attach the pressure screw on the cable gland according to the manufacturer s specifications M3 Tightening torque 0 5 Nm k K Tools 0 5x3 5 SW 5 09 99 000 0371 IV 16 IV Installation Instructions e HARTING IV 5 Han HC Modular 650 Note The following instructions are valid for both the one pole and multi pole connectors Step 1 The diameter of the cable s outer insulation may not be greater than 26 5 mm Strip the cable to a length of 23 mm Step 2 Guide the cable A through the hood B gt Step 3 Press the Han HC Contact C onto the end of the cable Hold the contact and cable end firmly in order to prevent twisting movement and torsion Use a torque wrench to apply the specified torque according to Table IV 2 2 All cable strands must be inserted completely into the contact chamber IV 17 IV Installation Instructions 9 HARTING Step 4 Put the support frame into the H structure of the HC contact The required coding for the HC contact can be made in 90 steps Step 5 Screw on the support frame on both sides with the hex bolts and using hex agon
75. al housing is especially advantageous when using shielded cables With shielded cable the structure of the EMC cable gland often does not allow the cable to be pulled through a gland and one part housing The cable gland has been newly designed for this connector it allows the user to see when the shield is attached so he can create a more secure connection The offset cable is inserted into the cable gland The contacts are then connected and the frame is secured After the pressure screw is tightened the shielding braid can then be drawn over the elongated enclosure on the cable gland Contact is then established using the self clamping clip This provides the user with a quick safe and convenient method for installing the contact and shielding connections The high current contacts Han HC Modular 250 Han HC Modular 350 and Han HC Modular 650 with a crimp or axial screw connection can be used for the actual power transmission The new cable glands are available in sizes M25 an M32 I 51 II Connectivity Products HARTING If a shield is not required then standard cable glands in the sized mentioned above can also be used The new power connector can be constructed as a three pole variant with Han HC Modular 250 Han HC Modular 350 and with HC 650 contacts with M25 or M32 cable glands A four pole variant is also possible with Han HC Modular 250 and with Han HC Modular 350 contacts and M25 cable glands Surface mount
76. al screws SW 2 5 Step 6 Insert the contact packet into the hood Tighten the four M3 retaining screws and attach the pressure screw on the cable gland according to the manufac turer s specifications M3 Tightening torque 0 5 Nm k U Tools Di ES t L 0 5x3 5 SW 5 09 99 000 0371 SW 2 5 IV 18 IV Installation Instructions cc HARTING IV 6 Installation instructions for the Han 24 HPR enlarged holder The following instructions describe the installation steps for putting the Han HC contacts 350 and 650 into the support frame for housings in the Han 24 HPR enlarged series also refer to chapter III 2 6 1 Step 1 Male Female Step 2 Male Female ft 1 5 130 2 NM Step 3 Male Female 10 1 NM M6 screw x 30 for bulkhead mounting housing M screw x 20 for hood IV 19 IV Installation Instructions IV 7 Coding options for the Han HC Modular contacts The high current contacts in the Han HC Modular 350 and 650 series can be coded This permits multiple connectors of the same type to be installed next to each other without any risk that connectors could be plugged into the wrong sockets The contacts are fitted with corresponding coding pegs and grooves for this purpose refer to Figure IV 7 1 Coding groove Coding peg Figure IV 7 1 Coding pegs and grooves on the Han HC Modular 350 contact The contacts have a hexagon shaped profile the Han HC Modular 350 or H shaped pro
77. and data Transmission of mid range power and data Transmission of mid range power and data Transmission of mid range power and data Transmission of mid range power and data Transmission of mid range power and data Han Modular Han Modular Han Modular Han Modular Han Modular Han Modular Ill Connectivity Products Contact insert module contact accessory Han K 8 24 8 24 pole PE Power usage 16 A 230 400V Control usage 10 A 160 V Crimp connection Han E module 6 pole 500 V Crimp connection Han ES module 5 pole 400 V Caged tension spring connection Han EE module 8 pole 400 V Crimp connection Han Quick Lock connection Han EEE module 20 pole 500 V Crimp connection Han E coax contact 1 pole plus shield Impedance 50 Q Crimp connection Install in Han Quintax module Han Q 2 0 2 pole plus PE 400 V Axial screw connection Han Q 2 0 2 pole plus PE 830 V only with shrink sleeve Axial screw connection Han 40 A module 2 pole 1000 V Axial screw connection Crimp connection III 35 HARTING t Product photo Combines power and signals in a single con nector Transmission of mid range power and data Transmission of mid range power and data Transmission of mid range power and data Transmission of mid range power and data Transmission of data and ETCS S21 Eurobalise 4
78. and cable side support housing with hood The interior interlock which can optionally protect against ac cidental opening securely holds both housings together after they are plugged in The Han Yellock also features two newly designed modules with Quick Lock and Crimp connection methods Both module variants have five contacts with a current carrying capacity of 20 A per contact and a rated dielectric strength of Figure lll 6 1 up to 500 V Han Yellock Construction schematic III 54 II Connectivity Products S HARTING The crimp connect modules can only be assembled with pin contacts A socket sleeve establishes the contact This sleeve comes integrated into the socket support by default The socket support can be inserted onto the touch protected pin contacts on either the cable side or on the device side This significantly simplifies the assembly process and results in less required product article numbers In addition to the classic one to one contact the five contacts can also be bridged with two way three way four way or five way bridges This quick and service friendly function already widely used with terminal blocks is now available for the constricted space within a connector The PE contact is on the housing and can be made using either Han Quick Lock or crimp contacts The non directional installation of the insulating base requires no tools and makes the assembly even simpler Just snap
79. are available in sizes 16 B and 24 B DT Grip panel er p Screw adapter i h top section E Screw adapter bottom section Figure IV 36 1 Grip panel and screw adapter As shown in the preceding figure the top and bottom sections of the screw adapter are similar in appearance In order to simplify installation and to tell them apart better the differences between the two screw adapter sections are described below IV 61 IV Installation Instructions P HARTING IV 36 1 Top section Product article number 09 00 000 5601 Description Screw adapter with retaining screw top section Included in delivery Two screw adapters Two knurled screws Imprint of the last _ Knurled four digits in the AA article number 5601 shown here Retaining hole for holding the Retaining holes for knurled screw contact inserts with thread M3 Figure IV 36 2 Screw adapter with retaining screw top section Product article number 09 00 016 5612 Description Screw adapter top section with grip panel Included in delivery Two screw adapters top section Two knurled screws One grip panel size 16 B One PE combi screw Figure IV 36 3 The contact insert is only an example male and female also possible IV 62 IV Installation Instructions E HARTING Product article number 09 00 024 5601 Description Grip panel Included in delivery One grip panel size 2
80. ation Instructions Hi Li 1 Push the cable gland and housing over the cable insulating sheath pe j t IP 20 housing IP 67 Data 3 A housing att T 2 Strip 24 mm from the cable sheath and 13 mm from the shielding braid 13 mm e 3 Prepare the wires for insertion into the splice element according to the colour coding 4 Fully insert the wires into the splice element until flush with the end 24 mm IV 80 IV Installation Instructions E HARTING 5 Engage the splice element with the RJ 45 data module r 6 Insert the data module and the splice element into the IDC assembly tool provided aar 7 Squeeze together the data module and IDC assembly tool to create the IDC connection mh 8 Remove the assembled data module from the IDC assembly tool 9 Add the upper metal shielding panel and press it over the cable shielding braid RM SE 10 Add the lower shielding panel snap it together with the upper metal shield until it engages with an audible click 11 IP 20 Data Push the housing over the assembled data module until is snaps in with an audible click 12 IP 67 Data 3 A Place the data module in the adapter and insert into the housing Secure the adapter using the sealing screw 13 Tighten the cable gland IV 81 IV Installation Instructions o HARTING IV 43 Han 3 A RJ45 8 pole and RJ Industria
81. aunting hosing must be additional ordered for masmay mounting Hoods appropiate only with traces Frame necessary Bugunou Bunsnou amp oepns pueuwrmq SBusnoj S usn en III 50 II Connectivity Products SOSO HARTING III 5 2 Power connector with two part housing The new power connector is based on sized 24B housings from the Han HPR series But in contrast to these housings it consists mainly of a hood with cover and contact support frame The open system achieved as a result sig nificantly simplifies the assembly process With this system you no longer need to first route the cable completely through the cable glands and housing and then push it back after the con tacts are connected The assembly process for the new system is completely accessible Only at the end is the hood pushed over the assembled connector and fastened This robust power connector has a compact design but still provides enough cabling space so that convenient assembly is possible even with large cable cross sections A mounting plate is used to fasten the power connector to the railway vehicle body or pivot mounting A custom fastening solution can also be implemented that is tailored to the installation position and space available in the customer application Threaded holes are available for connecting cable lugs These can be used to provide the external PE contact that is often required for railway applications The new section
82. bust metal housing IP30 IP40 ox 10x ports M12 D coded Robust metal die cast zinc housing IP 65 IP 67 7x 8x 10 100Base T X ports M12 D coded Robust metal housing IP30 19 inch mounting Compact and thin design 6x 8x 10x 10 100Base T X RJ 45 ports Variants with 2x 10 100 1000Base T X or 1x 2x 3x 100Base FX ports Robust metal housing IP30 Mounting on top hat rail Ring redundancy and or parallel redundancy V 8 o HARTING V Ethernet Networking Systems PEN M HARTING Functional Series Features Product photo Classification 6x 8x 10x 10 100Base T X RJ 45 ports Variants with 2x Ha VIS 10 100 1000Base T X or mCon 3000 ty 2x 3x 100Base FX ports Robust metal housing IP30 Mounting on top hat rail 8x 10 100Base T X ports M12 D coded 110 V DC and PoE variants Robust metal housing Managed IP30 IP40 Ha VIS mCon 4000 5x 10x 10 100Base T X ports M12 D coded Ha VIS mCon 7000 Robust metal die cast zinc housing IP 65 IP 67 7x 8x 10 100Base T X ports M12 D coded Robust metal housing IP30 e 19 inch mounting e Compact and thin design Ha VIS mCon 9000 V 9 V Ethernet Networking Systems EE e HARTING Table V 2 4 Overview of connectors for the cable side Male D coded Han M12 circular Crimp wire connection connector Clamping range 7 8 8 mm Use with D Sub contacts Male D coded HARAX M12 L 0 14 0 34 mm2
83. by a reduced contact resistance Actuator Han Quick Lock turned contact Spring Figure lll 7 3 Han Quick Lock termination technique III 60 Ill Connectivity Products S ISOS HARTING Figure lIl 7 4 illustrates this connection technology Figure lll 7 4 Han Quick Lock termination technique Assembly Manual Han Quick Lock j I P Remove cable jacket and strip the fine stranded wires 5 Push fine stranded wires into the Han Quick Lock contact and push the slide with a screw driver until it comes to a stop Removal Manual Han Quick Lock Please insert the screw driv er at an angle of 45 into the opening and lever the slide out Technical characteristics 0 34 1 5 mm 0 5 2 5 mm Terminal cross section AWG 22 16 AWG 20 14 blue Further information and a video presentation you will find on our Homepage www HARTING com III 61 III Connectivity Products r HARTING III 7 amp Crimp wire connection Crimp wire connections are classified as solder free electrical connections The specifications for this connection method are defined in DIN EN 60 352 2 The goal is to create solder free electrical connections using hand crimp ing tools or crimping machine which then fulfil the specified mechanical electrical and climatic conditions The key to this process is making sure that the tool crimping sleeve and wire are all well matched to each other The advan
84. cable side e Coupling with strain relief mechanism e Plastic housing Product article number 09 33 000 9991 Description Coupling with strain relief mechanism Included in delivery One coupling element with strain relief One coupling element atan H i Ir l Vie Lade e segzeichnungsschtider rmm Aun Figure IV 37 4 ah S Illustration of receptacle Figure IV 37 3 for the labelling tag Coupling with strain relief mechanism Tags 9 x 20 mm can be attached to the cavities on both sides of the cou pling elements The tags measuring 7 x 20 mm also fit onto the two drill holes in the plug in direction refer to Figure IV 37 3 One or two cable ties with max width of 5 mm can be used for strain relief Note Always attach the strain relief mechanism on the side of the contact insert that is opposite the PE terminal IV 70 IV Installation Instructions E HARTING Product article number 09 33 006 0401 size 6 B 09 33 010 0401 size 10 B 09 33 016 0401 size 24 B 09 33 024 0401 size 24 B Description Plastic housing Included in delivery 2 half shells with dummy plugs EH EDETE aa a Figure IV 37 5 Plastic housing Each housing has three cable outlets one on each face side and one facing up Two cable outlets can be closed with the dummy plugs that are included in the delivery These housings can be used with standard contact inserts and Han Modular Rectangular break out holes ar
85. ce for the DSA 200 pantograph Il 13 Il Application Examples 4 EE HARTING Stemmann Technik also offers side mount pantographs that can be used to collect current from the third rail The model Fb 218 contacts the underside of the current rail To provide a pluggable design the Han Q 5 0 in the Han 3 A HPR housing were used for the signals that control the pantograph a Heavy duty housings from the Han HPR series were chosen for this appli cation since the connector is positioned directly on the pantograph and is directly exposed to weathering influences Figure Il 12 3 Figure ll 12 4 Complete view of the model Fb 218 Han Q 5 0 in the Han 3 A HPR third rail pantograph housing II 14 Il Application Examples a C ssSsjSsedx ais gt ass l u HARTING Il 13 Connectors used in the coupling area of railway vehicles A classic railway application is the use of connectors in the wagon coupling areas The vehicle s coupling components have a pluggable design so that they can be more easily connected and disconnected during commissioning D and service work These connectors may also be located outside of the ve hicles under the floor so the same strict railway vehicle requirements for safety and reliability are relevant So here too the connectors of choice use housings from the Han HPR or Han M series Contact inserts for power transmission or for data bus signals such as the Han E Han
86. ched seal The order numbers are listed in the following tables Table IV 35 1 Han hood size 3 A with adhesive attached seal Housing jOrdernumber Remark Cable outlet M20 sideNo special bottom housing sections bulkhead mount ing surface mounting coupling or screw in housings are needed when using this contact insert It can be used with the standard housing types The housing types listed below can be used with housings from the Han 3 A HPR series Table IV 35 2 Han 3 A HPR black chromate housing Housing Ordernumber Remarks Bulkhead mountinghousing 109400080911 1 Bulkhead mounting housing angled 09 40 003 0953 M4 threaded tapped holes Surface mounting housing angled 19 40 003 0951 Cable outlet M25 through holes Surface mounting housing angled 19 40 003 0953 Cable outlet M25 M4 threaded tapped holes IV 60 IV Installation Instructions EE HARTING IV 36 Contact inserts with screw adapters Plug in connectors are often used to provide a pluggable solution for power and signals in the electrical cabinet Such connectors require no housing but do need a strain relief mechanism For these applications HARTING offers a secure connection via the grip panel and screw adapter refer to Figure IV 36 1 Knurled screws are used to interlock with the connector so that the plug cannot be accidentally pulled out The grip panel is used for the strain relief Grip panels
87. clamp terminal has a constant low voltage drop One conductor per termination Slot for screwdriver D I Installation e Wire cross section 0 14 2 5 mm Insulation stripping length o Han ES Han HvES Han K 4 4 control contacts 7 9 mm o Han ESS 9 11mm An installation schematic is shown in the following figure A Screwdriver width 3 0 x 0 5 mm III 59 Ill Connectivity Products rCr HARTING Han Quick Lock The Han Quick Lock termination technique was designed to increase effi ciency during the assembly of plug in connectors This connection method combines the reliability and ease of use of the stan dard cage clamp termination with the minimal space requirement of the crimp connection It is the only connection method that can be installed in the field that features a contact density comparable to a crimp connection III 7 3 Han Quick Lock termination technique Features Quick simple and robust connection Can be installed on site without any special tools Resistant to shock and vibration just like the standard cage clamp termination Mating compatible with the other proven Han contact inserts Figure Ill 7 8 shows the layout of a contact with the Han Quick Lock ter mination technique Note the spring which applies radial clamping pressure around the wire strands This special connection method is characterized
88. connection I 33 HARTING w Product photo Data trans a d mission roug i 3 Data trans mission Data trans mission including Ethernet Data trans mission including Ethernet Data trans mission Video signal transmission Data trans mission including Ethernet Transmission of mid range power and data Transmission of mid range power and data III Connectivity Products Current A Contact insert module contact accessory Han 8D 8 pole 50V AC 120V DC Crimp connection Han Easy Lock connection H H Han O 7 0 7 pole plus PE 400 V Crimp connection H Han Q 12 0 12 pole plus PE 400 V Crimp connection power contact Han Quick Lock connection PE Han Han DD module Modular 12 pole 250 V Crimp connection Han Quick Lock connection Han Han DDD module Modular 17 pole 160 V Crimp connection Han EN Han ES 6 10 16 24 pole PE 500V Crimp screw and cage tension spring connections H Han EE 10 18 32 46 pole PE 500V Crimp connection Han EEE 40 pole 64 pole plus PE 500V Crimp connection H Han Q 5 0 5 pole plus PE 230 400V Crimp connection Han Quick Lock connection III 34 an an an an an an an o HARTING d Product photo Data trans mission Transmission of mid range power and data Transmission of mid range power and data Transmission of mid range power
89. ction with integrated T functionality 360 shield connection Very space saving compact design Large space for wiring Cage tension spring connection with integrated T functionality 360 shield connection Very space saving compact design Large space for wiring Cage tension spring connection with integrated T functionality 360 shield connection Very space saving compact design Large space for wiring Cage tension spring connection with integrated T functionality 360 shield connection Very space saving compact design Large space for wiring 360 shield connection Very space saving design Large space for wiring HARTING Interior of railway wagons Contact for se rial and parallel signals in MVB applications Interior of railway wagons Contact for se rial and parallel signals in WTB2 applications Interior of railway wagons Contact for serial and parallel sig nals in CAN bus applications Interior of railway wagons Contact for serial and parallel sig nals in Profibus applications Interior of rail way wagons Electrical cabi net distributor boxes contact of serial and parallel signals in bus application or interface ap plications I 24 Ill Connectivity Products HARTING Product Features Areaofuse Product photo InduCom housing With cable outlets straight or to the side for screw interlock InduCom housing With
90. d automatically III 80 HARTING Ill Connectivity Products The Han 46 EE contact insert consists of a total of 46 contacts plus PE They are distributed across four rows 2 outer rows with 13 contacts each and 2 inner rows with 10 contacts each The multiplier is designed so that the data on both outer rows can be mul tiplied three times per contact The connections on both middle rows have one to one through contacts The multiplier can be installed in the sized 24B bulkhead mounting housing Figure Ill 8 3 illustrates the layout Figure Ill 8 3 Han 46 EE sectional view The installation instructions for this product are described in the Installation Instructions Chapter III 81 III Connectivity Products r HARTING III 8 5 Cable glands Table Ill 8 9 Metal and plastic cable glands with metric threads x Partnumber read M ames p SW E Nm C gs m III 82 Ill Connectivity Products Table lll 8 10 EMC cable glands for metric E E a cable entries IP 68 d cable O D Part number he Cc 19 62 000 5080 19 62 000 5081 19 62 000 5082 19 62 000 5084 20 20 20 20 ON On 19 62 000 5090 25 19 62 000 5092 25 so aj ow O E N gt J 9 C o oj o eo C 19 62 000 5094 32 19 62 000 5096 32 C C gt co o 19 62 000 5097 40 19 62 000 5098 40 N e N O Wu Table III 8 11 Blanking piece
91. d distributor strain relief boxes Note a HARTING mounting frame should be used when installing housings to thin walled metal panels or when arrange multiple housings in a row refer to Chapter III 8 1 III 5 Ill Connectivity Products HARTING Ill 2 2 Installation location of the hoods and housings The overview table below shows which hood and housing types can be used in which locations and for which rail applications This is only a general overview Several different hood and housing types are appropriate for use in some applications and the specific details should be established depending on the particular project IL 2 21 Overview of housings and locations for industrial connectors Location Han Han Han Han Han Han Screw Interior inside HPR M B Yellock Eco Snap adapter Driver s console Electrical cabinet pape ue eee MPO III Connectivity Products aes HARTING Location Han Han Han Han Han Han Screw Exterior outside HPR M B Yellock Eco Snap adapter 1 Depending on the particular project requirements III II Connectivity Products 5 HARTING III 2 2 2 Overview of products and locations for interface DIN connectors Location InduCom InduCom MITRAC Interior inside 9 housing Driver s console asss III 8 I Connectivity Products Location Interior inside III 9 HARTING MITRAC housing
92. d frame 09 14 000 99092 15 coding options with two hinged frames 1 4 pieces connector top section and bottom section 2 4 pieces connector 3 Refer to Chapter IV Installation Instructions Coding Elements Please contact us for more information if these coding options are not adequate for your requirements III 4 Ill Connectivity Products Goding elements TT Coding pin Han E Han EE Han Q 5 0 Han Q 8 0 09 33 000 9954 Coding pin Han D Han DD 09 44 000 9915 Coding pin for male insert Han Q 7 0 09 12 000 9901 Coding pin for female insert Han Q 7 0 09 12 000 9902 Coding pin Han Q 12 0 09 12 000 9924 Coding peg Han Yellock 11 00 000 9501 Coding with loss of a contact The male contact opposite the coding pin cannot be used Coding with loss of a contact The male contact opposite the coding pin cannot be used 6 way coding without loss of any contacts 6 way coding without loss of any contacts 16 way coding without loss of any contacts 25 coding options without loss of any contact with clear position mark on cast part of housing I 75 mme HARTING d Ill Connectivity Products IIl 8 3 Accessories o HARTING Clamps and strain relief frame When working with connectors the issue of strain relief mechanisms for the shield or PE connection is a continually reoccurring theme HARTING offers a comprehensive line of frame p
93. e If you do not take this step the insulating base can be damaged and the interface may malfunction The recommended torque is 14 Nm for the Han HC Modular 350 and 16 18 Nm for the Han HC Modular 650 These contacts are intended only for installation in HPR bulkhead mounting housings Hex screw Spring washer Counter support Cablelug Flat washer Figure IV 9 1 Screw terminal connection IV 23 IV Installation Instructions 9 e HARTING IV 10 Installing the high current contacts in the Han 48 HPR housing series Figure IV 10 1 shows the installation sequence for high current contacts in the Han 48 HPR housing series The following instructions assume that he cable glands have been installed already e The support frames with the contacts have al ready been fastened to the cover with the bolts Pre assembled customized connectors sets are available on request When installing you should connect the middle or inside contact first Guide the cable ends through the unscrewed fit ting nut and seal The installation notes concerning the cable con nection to the high current contact can be found in Chapter IV of the Installation Instructions The housing can be assembled after the connec tion has been put together and inspected Figure IV 10 1 Han 48 HPR Here the cover with the contacts on the support frame must be inserted into the housing hooded or surface mounting housing fro
94. e dies ovailable at DANIELS for the HX4 tool frame As new requirements evolve the ongaing process of developing new de sets continues CARE OF TOOL We strongly recommend that you 1 DO NOT immerse tools in cleaning solution 2 OO NOT spray oil inta tool to lubricate A DO NOT attempt te disassernble taal or make repairs This is o precision crimp tool and should be handled os such DMC offers campiete refurbishing and recalibration services DMG specially engineers and manufactures complete teel kits to satisfy individual customer requirements such as total aircraft support general shop maintenance or production on board ship and vehicle service etc IV 35 IV Installation Instructions qi HARTING IV 19 Crimping tools for D Sub contacts 09 99 000 0501 General information 1 Designation AFMB M 22520 2 01 refers to basic hand tool without positioners Wire crimp range 20 AWG to 32 AWG 2 The tool has a double action ratchet Note that the tool cannot be opened without completing the cycle Tool preparation Tool in open position 1 Tool must be in open position SCH ES 2 Remove safety clip from positioner guide MT A crimped 4 Insert positioner into positioner guide and turn 90 degrees until bayonet pins lock 5 Install safety clip unto positioner guide optional 6 Wire size and corresponding selector num ber are shown in data plate 9 o o 2 D 2 3 S
95. e fully opened e t prevents the crimp tool from opening before the crimp cycle is completed Early release It is possible to effect an early relase of the safety device with a screwdriver if the crimp is faulty The safety device is released by turning right or left The load must be taken off the jaws by applying slight pressure to the handle Damage the crimping stamp will thus be prevented if the contact does not lie correctly in the profile Do not use force to open and shut the crimp tool Lubricate all moving parts weekly Locator The crimp tool is equipped with a locator for all specificifies contacts Crimping Procedure Insert the contact into the proper crimp profile until it is stopped by the locator e Insert the stripping wire into the contact e Crimp the contact by closing the hanles until the controlled cycle mechanism release e Upon release the handles will open automatically and the crimped contact can be removed Pullout forces according to DIN IEC 60 352 2 A2 Tightening Torque s contact We reserve the right to effect changes in design which may arise from improving the quality of our products new developments or because of changes in the manufacturing process IV 31 IV Installation Instructions HARTING IV 15 Crimping tool 09 99 000 0303 CRIMPING INSTRUCTIONS Open the tool Place the terminal into the correct die nest 1 Particularly close the tool until the terminal is held
96. e located near the cable outlets These can be used for cable connectors of up to 5 mm width Both housing shells are held together in the plug in area by the mounting screws from the contact insert The two housing shells can be disconnected from each other using a screw driver 3 5 x 0 5 Labelling tags 7 x 20 mm or 9 x 20 mm can be attached using the support receptacles for the dummy plugs IV 71 IV Installation Instructions HARTING IV 38 Coding elements There are two variants of coding elements that can be used to code plug in connectors e Coding with locking studs e Coding with guide pins and guide sockets IV 38 1 Coding with locking studs When coding with the locking studs two retaining screws per contact insert are replaced with locking studs The locking studs are arranged so that they will hit when an attempt is made to insert a connector into the wrong mate Figure IV 38 1 Proper combination Retaining screw Locking _ Locking stud stud Figure IV 38 2 Wrong combination gm Figure IV 38 3 Proper combination IV 72 IV Installation Instructions E HARTING Coding for housing with a contact insert sizes 10 A 16 A and 6 B to 24 B l r H id VI M i EN n L Le W a D c M F M F M F M F M F M F Locking stud M Male pin insert O Retaining screws F Female insert Coding for housing with two contact inserts sizes 32 A
97. e many combination options of housings contact inserts and contacts Possible combinations are marked with a kr An overview of the typical cable gland sizes M threaded size and clamping range is provided to compliment the connector components overview III 46 HARTING Connectors for 100 to 200 A Han 24 HPR housings Table lll 5 1 Han 24 HPR hood section overview Ill Connectivity Products ewled h III 47 pm HARTING Connectors for 100 to 200 A Han 24 HPR housings Table IIl 5 2 Han 24 HPR housing section overview Ill Connectivity Products i uu y S ie md umu Gt oL Ga w toz DH A 0002 0511 zn pejDue ZEN UEH LRU Dl SE W I vest pajBue org uH ll BE MALI SE 9i RE umu GE OL WW t l zl A000 n III 48 HARTING ura op brjeu aua A425 8 0 unu OF xu oj dn Bn epe r j eu arde pang ugar m ut uY Connectors for 250 to 650 A Han 24 HPR housings Table lll 5 3 Han 24 HPR housing overview Ill Connectivity Products i 35 mm available 0 with hexagonal adapter 16 III 49 HARTING Connectors for 250 to 650 A Han 24 HPR enlarged hood and housings Table lll 5 4 Han 24 HPR enlarged housing overview III Connectivity Products Von en 3 25 lg unu gi 8 uuu GL xeu j dn Bn OPES JAN CULLEN Mert 3 v OE ANE I i E 9 gt Bulkhead omo
98. e network One key requirement for many applications is that the network is continually available and is resistant to outages The HARTING management software supports the rapid spanning tree protocol for creating loop free and outage resistant networks The actual configuration and management for the Ha VIS mCon switch is not difficult at all the switch can be configured using SNMP tools network man agement software or simply using an internet browser via the web interface The HARTING Ha VIS mCon switches are versatile provide professional solu tions for operating Ethernet networks and are easy to install and administer Besides the Fast Ethernet interface the Ha VIS mCon also provides Gigabit and fibre optic ports V 4 V Ethernet Networking Systems gt v HARTING Table V 2 1 Management functions Basic Functions store and Forward Switching Mode IEEE 802 3 Manual and Dynamic IP Address Assignment Auto Negotiation on off Port Speed 10MBit s 100MBit s Half Fullduplex Port disable enable Link Up Down Trap disable enable Flow Control disable enable Network Link Layer Discovery Protocol IPv4 RFC 791 903 951 1293 1519 Protocols Port Settings Ethernet ARP RFC 826 RFC 2521 1191 ME 1788 792 SE Firmware Import und Export Via TFTP Configuration Import und Export Via TFTP Tine Ga Manual time setting RFC 1305 5 Simple Network Time Protocol SNTP RFC 4330
99. ead mounting Han EMC B with conduc tive surface O ring seal Figure lll 3 5 The electrical contact between the hood and housing sections is established by means of a metallic adapter frame III 28 II Connectivity Products ee OO HARTING IL A Contact inserts and contacts The contacts and contact inserts of the Han industrial connectors can be used in electrical interfaces with currents ranging from just a few milliamps all the way up to 650 amps Multi pole contacts inserts such as the Han E Han EE or Han D series Han DD modules from the Han Modular series and high current contacts from the Han HC series are all available for these connections These product series are described on the following pages All contact inserts and contacts are listed in order of increasing current strength in the tables Table UL 4 1 and Table Ill 4 2 HARTING s connectivity products are plug in connectors As with all plug in connectors you should never pull out the connectors while there is a live voltage present The Han industrial connectors have been designed in accordance with IEC 61 984 They have the following technical specifications Insulation resistance gt 1010 Q Mating cycles 2 500 with contact resistance 5 mQ The DIN 41 612 IEC 60 603 2 directive is valid for DIN 41 612 connectors Insulation resistance gt 1012 Q Mating cycles gt 500 mating cycles hazardous gas test IEC 60 603
100. ecifications given here come from the catalogue Industrial Connectors Han According to DIN EN 60 228 VDE 0295 concerning cables and insulated lines a cable s cross section is determined by the conductivity Q km and the maximum wire diameter A minimum wire diameter is not specified For example a rated cross section of 95 mm is greater than a real geometric cross section of 89 mm Before beginning installation you can check the connection options for the cable you are using at our accredited HARTING laboratory Additional information about the axial screw wire connection method Strain relief The cable should be mechanically supported at an appropriate distance from the connector in order to avoid damage to the contact e g damage resulting from twisting or pulling of the cable The maximum gap for such a strain relief support mechanism is specified in the following table Table IV 2 1 Retention gap for easily accessible cables DIN VDE 0100 520 2003 06 Outer diameter of the cable mm Maximum gap for the retention support mm x Horizontal vertical 400 9 lt D lt 15 300 400 15 lt D 20 350 230 20 D 40 400 550 Maintenance for the terminal connections In order to avoid any splitting of the wire strands it is only permitted to reapply torque to the connection one time during the entire application lifespan Cable The axial screw connection is suitable for finely stranded lines accord i
101. elease lever 10 in direction Release and hold it there Pull out the contact strip 6 4 from the In dexing Unit towards the contact roll 2 Remove the contact roll 2 by undoing the knurled nut 3 Safety ratchet The hand crimp tool can only be used after it has been opened completely Each crimp pro cess has to be done fully before the tool can be opened again This guaranties a good quality crimp each time Early crimp unclamp It is possible to open the tool during crimping if necessary e Slightly hold together the grips of the tool Open the safety barrier 11 on the rear side of the tool by turning left Open the grips of the tool to release the partially crimped contact Maintenance Remove any existing material and dirt and clean the crimp zone regularly Check the crimp zone of the tool for correct closing clean all moving parts These should move smoothly in operation and lubricate them Use machine oil SAE 20 In case of any identified damages let only authorised personal attempt any repairs Tool is for crimping purpose only Use with HARTING crimp contacts only Protect tool against high humidity and dust Tab IV 21 1 Overview of wire cross sections for DIN 41 612 crimp contacts and the corres ponding crimping tool Wire cross Insulation Contact HARTING Number of Crimping tool Profile setting AWG section mm diameter of ida Order number contacts opt ions on the crim cable mm ti
102. elect positioner for contact to be b poat um Sd lt 7 With tool still in open position raise and Positioner Selector knob rotate selector knob until number indi blue guide Bayo cated on data plate for wire size to be net crimped is in line with Sel No arrow pins Crimping instructions SS Posi 1 Insert contact and prepared wire into in Data tioner denter opening from side opposite the plate K positioner series 2 Squeeze handles together until ratchet re leases Handle will return to the open po All dimensions in Inch sition Remove crimped contact and wire mus JA 8 JS Removing Positioner 1 Remove safety clip and reverse procedure described in step four 4 above i SA eez l Table IV 19 1 Caging limits Caution Selector A 0 0001 B 0 0001 Do not crimp gauge No Go No Go 1 0 0130 0 0180 j 2 0 0160 0 0210 GEEN we REO Bp 3 0 0190 0 0240 JE Spe 4 0 0220 0 0270 Jd TH 5 0 0260 0 0310 G125 6 0 0300 0 0350 M22520 3 1 7 0 0340 0 0390 8 0 0390 0 0440 IV 36 IV Installation Instructions Gauging instructions Go gauging Operate tool to fully closed position Maintain firm hand pressure on the tool handles Insert go gauge end as shown Gauge must pass freely between indenter tips Gree Indenter HARTING No Go gauging Operate tool to fully closed position Maintain firm hand pressure on the tool handles Insert No Go gauge e
103. en devote a chapter on the increasingly popular topic of network systems in which solutions and Ethernet products suitable for railway and train use are described The chapter VI shows a selection of HARTING s customized solutions that are designed to fit individual requirements HARTING was founded in 1945 The HARTING Technology Group now employs over 500 en gineers to design a variety of products and so lutions in the fields of machine construction railway systems wind power facilities factory automation and telecommunications These solu tions cover connectivity transmissions network systems production mechatronics and soft ware design The HARTING Group currently employs about 3 000 employees throughout our 32 regional subsidiaries In May 2006 HARTING became one of the first companies in Europe to be certified for IRIS compliance the International Railway Industry Standard This recognition is a great honour for HARTING but also a challenge for us to meet the future requirements and needs of the railway industry l 1 Foreword _ C 00 le S HARTING l 1 Connections and network systems for railway vehicles Connections are often implemented using pluggable connectors In recent years such connectors have been playing a greater role in railway vehicles This is because of the enormous time and cost pressures that operators are put under Modern railway vehicles have a modular design in order to he
104. entries They have become the optimal solution when outstanding shielding attenuation characteristics and mechanical stability are an absolute must The spacious interior of the In duCom 9 variant allows circuit boards for bus systems or customer specific applications to be integrated The EMC requirements for an interface stipulate that the rated shielding attenuation potential or the degree of interference immunity must be high enough so that the electromagnetic field surrounding the connector cannot interfere with the signal transmission inside the connector In the opposite direction the shielding characteristics also prevent the signal transmission on the interface from emitting interference that could interfere with the surrounding devices and components These requirements are all completely met by HARTING s crimp flange and the full metal InduCom hoods with their labyrinth double labyrinth structure Figure lll 2 14 Figure lll 2 15 Double labyrinth Labyrinth The crimp flange connection also provides a very effective strain relief and anti twist protection for the cable even ander extremely harsh industrial conditions In addition cables with a diameter of up to about 13 5 mm can easily be connected to the housing for a 9 pole D Sub connector I 22 Ill Connectivity Products aseNo0 ya3 OT2 n HARTING The crimp flange provides you with consistent repeatable high quality that doesn t depend on
105. er to create a reliable connection be sure to follow these points he wire combination should be appropriate for the material and surface he cross section in the crimping sleeve must be appropriate in relation to the total cross section of the wire he requirements concerning the tensile strength and contact resistance for the connection according to EN 60 352 2 must be met All processing steps should be carried out carefully he wire strands may not be twisted Be sure to maintain the creepage and clearance distances according to the relevant standards I 64 Ill Connectivity Products E M FP HARTING IL Zb Axial screw connection An axial screw wire connection can be used to connect stranded and finely stranded wires This connection method was designed for connecting wires with large cross sections in a tight space without any special tools Wires with cross sections ranging from 2 5 to 185 mm can be connected This connection method is suitable for use in railway wagon applications be cause it offers excellent reliability and resistance to shock and vibration n fine stranded cable Nav axial cone plastic insulator Figure Ill 7 5 A schematic of the axial screw connection Figure IIl 7 5 shows a cut out view of a contact with an axial screw connec tion The installation instructions for the corresponding contact inserts are de scribed in Chapter IV Installation Instructions Ill 65
106. erat ing the changeover units 09 99 000 6001 6002 2 Plug gauge with 1 00 mm 1 30 mm 1 55 mm 1 80 mm 2 00 mm 3 The base device 09 99 000 0810 is required when operating the tool heads 09 99 000 0813 0814 Only the male contact 09 15 000 6107 6127 6307 gt Silver Gold Han GoldTec or the female contact 09 15 000 6207 6227 6407 gt Silver Gold Han GoldTec should be used for wire cross sections 0 14 and 0 25 mm2 In the current version the crimping tool 09 99 000 0110 is deliv ered complete with locator The locator can also be ordered separately under order number 09 99 000 0376 The following pages contain the operating instructions and notes for the HARTING crimping tools IV 26 IV Installation Instructions ee HARTING IV 12 Crimp contacts for wire cross sections from 10 to 240 mm n tx Figure IV 12 1 pa rn 0 9 Crimp contact and contact sleeves eo 2 for Han HC Modular 350 For wire cross sections in the 10 240 mm range HARTING offers crimp contacts with a crimp zone in compliance with DIN EN 46 235 So for these contacts you can use tools equipped with DIN crimping jaws in order to meet the requirement for a pressing force of 13 tons 130 kN The contacts can be used with stranded wires in accordance with IEC 60 228 Class 5 The following table contains an overview of the available crimp contacts Table IV 12 1 Crimp contacts for wire cross sections greater than 10 mm Contact
107. es electrical cabinets and distributors must be custom designed to fit the environmental surroundings A good example of such a system solution is the complete electrical cabi net integrated into the front of a locomotive which HARTING provided for the Vossloh MaK 1000 BB HARTING was the single source for all the panel work assembly professional testing and also procured the third party materials for the electrical installation The modern and precise manufacturing facilities at HARTING are well suited for sheet metal processing and customized production of electrical cabinets boxes and consoles TI S Figure VI 6 1 Figure VI 6 2 Vossloh Locomotive MaK 1000 BB Front of the vehicle MaK 1000 BB Figure Vl 6 3 Front of vehicle with opened electrical cabinet VI 8 VI Customer Specific Solutions ee HARTING VI 7 Interior Cabling for rail vehicles HARTING service does not end after we have delivered the connectors it also includes a wide range of engineering and assembly services which take individual customer requirements into account Complete cable assemblies for vehicles can also be made Figure VI 7 1 Sample cable harness Figure VI 7 2 Assembled connectors VI 9 VI Customer Specific Solutions 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 HARTING VI 8 Connector sets and accessories Electrical junctions are typically made up of many components which all have to be ordered separately HARTI
108. esessrriseereerserrrrseeserrsssrees 17 III 2 8 Han B housing locking mechanisms 20 Ill 2 9 Han Easy Lock locking lever a 21 III 2 10 InduCom hood 22 III 2 11 Housing DIN 41 612 IEC 60 603 2 26 Hoods and Housings for EMC requirements 27 Contact inserts and contacts 29 Ill 4 1 Han Modular nnne ener 31 Ill 4 2 Han HC Modular a aa keke ke 32 Power GONMECCLOMS m 46 III 5 1 Power connector with one part housing 46 III 5 2 Power connector with two part housing 51 Han Yellock housing and contact inserts 54 Types of connections used in connectors 56 HIE d Screw NNN EE 58 Ill 7 2 Cage clamp terminal 59 Ill 7 3 Han Quick Lock termination technique 60 Ill 7 4 Crimp wire connection 62 Ill 7 4 1 Crimp connections for wire cross sections O TO Hin beet TT 63 Ill 7 4 2 Connecting multiple strands in a single crimp cont
109. et Network Solutions Automation IT III 3 Ill Connectivity Products ZRBAmA O OA SSS HARTING Ill 2 Hoods and housings overview III 2 1 Overview of Han hoods and housings and contact inserts Hood and housing Han HPR Hood and housing Han M Hood and housing Han B Hood and housing Han EMV B Hood and housing Han Yellock Hood and housing Han Eco IP 68 IP 69 K corrosion resistance EMC safe screw interlock For harsh environmental requirements IP 65 stainless steel locking lever IP 65 Han Easy Lock locking lever IP 65 67 EMC safe Han Easy Lock locking lever IP 67 Press button interlock inner locking mechanism Plastic IP 65 locking lever External use on railway wagons External use on railway wagons Internal use on railway wagons Internal use on railway wagons Internal use on railway wagons Internal use on railway wagons III 4 Ill Connectivity Products 3 OSOS wa Hood Resistant to shock Internal use and housing and vibration in on railway Han Snap compliance with wagons IEC 60 068 Electrical BN 74 018 cabinet distributor boxes Screw adapter Interlock by Internal use refer to the means of knurled on railway Installation screws wagons Instructions Gripping area Electrical for additional for the shield cabinet details connection an
110. event any such uncontrolled opening In exterior installations the advantage of the screw interlock over the locking lever is that it can only be opened using a tool in a controlled fashion In addition to the screw interlock the HPR housings feature IP 68 IP 69 K protection when they are locked shut They are also corrosion resistant and have very good EMC characteristics The Han M series is a rail compliant option for some applications It pro vides the same high level of corrosion protection but has a smaller size com pared to the Han B series and does not have a screw interlock mechanism The robust stainless steel lever is designed so that the locking force is ap plied by the Han Easy Lock locking lever It is also a good idea to imple ment additional measures dependent on the installation location in order to prevent an unintended opening Such measures include blocking devices protective panels and the proper choice of location for the installation Il 3 Il Application Examples ee SSS SS HARTING II 3 Motor connection The motor connection has a pluggable design so that the connection be tween the traction bogie and the vehicle is versatile and quick to connect Each connector is designed to connect two drive motors to improve the effi ciency level There are five high current contacts of the type Han HC Modu lar 350 three power contacts one return wire and one radial earth for each motor Th
111. file the Han HC Modular 650 so that they can be installed in different positions in the support frame Refer to Figure IV 7 2 and Figure IV 7 3 for additional details Figure IV 7 2 Figure IV 7 3 Hexagon shaped profile of H shaped profile of the Han HC the Han HC Modular 350 contact Modular 650 contact IV 20 IV Installation Instructions HARTING The support frames are put onto the hexagon or H profile of the contacts This allows a variety of different coding positions to be configured Figure IV 7 4 illustrates the available coding positions for the Han HC Modu lar 350 contact There are six different positions that can be coded Figure IV 7 4 Coding options for the Han HC 350 Modular contacts The Han HC Modular 650 contacts have up to four coding positions avail able refer to Figure IV 7 5 Figure IV 7 5 Coding positions for the Han HC 650 Modular contacts Before beginning the assembly be sure that both mating sides of the coded positions fit to each other and can be plugged in together IV 21 IV Installation Instructions HARTING IV 8 Doubled contacting with axial screw contacts In general it is possible to connect two cables per axial screw contact In order to eliminate any remaining risks we recommend consulting with us before this installation Our laboratory can then check your contact cable configuration for the appropriate stripping lengths torques pull
112. g yela 9 a 0I 9 ZIS P EE g Ue H Ue Hl UE He EH wu M U1DpIA 8301 r asesn Jequunu uoneJ1sn ejduieg E 14918 N ww y 1u3 eH ER N uondioseq Suoneoyioeds eoruuo9 gs MIS RW po sz se ez 99 a zn ese s9 ze e UEH UEHJ UEHI UEH l IIl 79 III Connectivity Products ae HARTING III 8 4 Han EE Multiplier The Han EE multiplier was designed for the purpose of distributing data and signals inside railway vehicles Figure lll 8 1 Figure lll 8 2 Han EE multiplier Han EE multiplier variants This product is designed to be used with the Han 46 EE contact insert It is available in two variants Table lll 8 8 Han 46 EE multiplier Product article ae Position in One Han 46 EE contact insert unpopulated One Han 46EE multiplier populated Male 09 32 046 5651 with 46 long contact pins version 4 M3 retaining screws 2 PE panels pre mounted to contact 4 e zzg ij pawa Han 46 EE contact insert Ron MM with 46 contact One Han 46 EE multiplier populated Female 09 32 046 5751 with 46 short contact pins version 4 M3 retaining screws EES 2 PE panels pre mounted to contact insert Note The female version has an additional contact between the multiplier and the Han 46 EE female insert The male version has contacts that are measured so that they are long enough to be inserted through the Han 46 EE male insert The correct contact length is then derive
113. geoyod 9 W 0 6 0 NYH 100 00 ZI 60 019144N OLSSNIG outen en eZ 6000 9200 fayeuoqueofjod soon UBIH J 0 Z O ueH ZSZZ Z00 ZI 60 oa AN 018SNIG OA 610 sizo eez ooo igo feruoqieakod eBejoA uH W 0 Z 0 ueH ZG9Z Z00 ZI 60 019144N OLGSNIQ OA 610 een eez vioo rop e1euoqieoKod lew dujJo OGZ JeINPOW OH ueH IZLE LOO 11 60 TW 33 uonod jqewwe y puta uonJod 1U8I9M enjeA Sureau 9 qeuuuue J peoj au een H99H jo qu8lew eui spuepuels Je1491e A uondiosep 14009 Jequinu qed VII Selected Standards Relevant to Railway Applications VII 10 VII Selected Standards Relevant to Railway Applications HARTING L019144N OLGGNIQ OA Peif 6 2 0 DE L019143N OLSSNIG OA 610 DR 62 L01914N OLGSNIQ OA en 491 0 EG L019144N OLGGNIQ D O V61N LOL9LIAN OLGGNIQ OA Peif LOL9LIAN OLSSNIG OA Peif L019144N OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLGGNIQ OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif LOL9L44N OLGGNIQ D O V61N L0L9LJ4N OLGGNIQ OA Peif L019144N OLSSNIG OA Peif LOL9L44N OLGGNIQ D OA V61N LOL9LIAN OLGGNIQ OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif LOL9LIAN OLSSNIG OA Peif L019144N OLGGNIQ 1 O Fell eui
114. gon couplings and pre assem bled system cable We would be happy to talk with you if you have any special requirements or if you are looking for a switch that is not shown here V 2 V Ethernet Networking Systems gi M 2 V HARTING V 2 Ethernet Switches for transportation Switches for locomotives passenger wagons and control wagons are ex posed to vibrations electrical fields and other external influences This field of application demands extraordinary reliability and longevity from all electri cal components The EN 50 155 standard stipulates these requirements The Ha VIS eCon Ha VIS sCon and Ha VIS mCon lines of switches support the railway and bus industry requirements V 2 1 The Ha VIS eCon unmanaged switch Ethernet Switches in the Ha VIS eCon series can be used for Fast Ethernet 100 Mbit s and are Plug amp Play Both line and star topologies as well as combinations of both are supported Depending on the type between 6 and 10 Ethernet devices can be connect ed to the Ethernet Switch via RJ45 twisted pair or M12 ports Modules are also available to connect two further Ethernet devices by means of fibre op tic ports 100BASE FX Full Duplex with SC connection technology The Ethernet Switch operates as an unmanaged switch in the store and for ward switching mode supporting auto crossing auto negotiation and auto polarity V 2 2 The Ha VIS sCon configurable switch Ethernet Switches from the Ha
115. h in frame and used for controlling and monitoring a brake system The data sensor and ac tuator signals is controlled by I O units The key features are the connectors take up a minimal amount of space they have a consistent shielding design with EMC housings in 19 inch metal component carrier and they have excel lent signal quality Since the push in frame is used in the vehicle interior an IP30 level of protec tion is completely adequate Figure ll 14 1 The Siemens Velaro RUS L W Figure ll 14 2 Figure ll 14 3 Brake controls InnoTrans D20 full metal housing II 17 Il Application Examples 4 e HARTING II 15 List of references since our founding in 1945 HARTING has delivered connectors to the rail way Recently we have also begun delivering active components and Ether net cable for rail applications The following list gives some examples of train platforms and railway projects Tram lines street cars LRV Frankfurt Germany Bochum Germany Dresden Germany Innsbruck Germany Graz Austria Houston USA Hiroshima Japan Metro underground railways Bangkok MRTA Shangahi Line 10 Dubai Metro Red Line Delhi Metro Valencia Metro New York NYCT Madrid Metro Chengdu Metro Berlin Tram Moskau Metro Wien Metro Oslo Metro Regional commuter trains express tram lines Malaysia Kuala Lumpur Airport Express KLIA Norwegen Oslo Norwegian State Railway G
116. he axial screw connection method e Strip the wire strands according to the preceding table The stripping length depends on the type of contact and contact insert that are being used Insert the wires strands in the contact chamber until the insu lation is flush with the contact Hold the wire strands in position Use the corresponding hex agonal driver at the plug in side and tighten with the proper torque The size of the hexagonal driver and the torque value depend on the type of contact and contact insert being used These values can be found in the preceding table zz2Z Ee ee NS rM xa W N 8 FANS T E oPFEPFFFEFP n 5 dil j AN BARA TUB B yr AA E FE KN D DEEN S Figure IV 3 1 A schematic of the axial screw connection IV 9 IV Installation Instructions qi HARTING The installation instructions for the Han K 3 0 and Han K 3 2 contact in serts both straight and angled are detailed in this section These instructions vary according to the installation the contact inserts are intended only for installation in Han HPR housings Installation in straight hoods 19 40 024 0461 3 x M25 for Han K 3 0 19 40 024 0471 3 x M25 1 x M20 for Han K 3 2 Han 24 HPR hood straight Tightening torque 8 10 Nm please see catalogue information SW 5 4 XEM T m SS w T ees Kl gt Stripping length for Han
117. he crimp teal handle and slide the die removal taal between the die and tool bady See Figure 35 Pull handle open with o snap action The die will be released and can then be removed by hand PERMANENT DIE ASSEMBLY 1 Install dies in crimp tool z Urive lock pins supplied with dies through holes and flush with outside surfaces Long pin through tool body and short pin through push red see Figure 4 NOTE Die removal tool part number HX3 82 is FIG 4 furnished with crimp tool lT die removal teal is not available a rod approximately 3 16 NOTE Use only i series dies with HX4 diarneter X 1 1 4 long may be used erimp tool HEX DIE GAGING 1 Hold the tsel handles firmly closed 2 Insert the GO gage green member as shown gaging only those hex flats parallel 1o the die face parting line The GO gage member should freely enter the die cavity B Attempt to insert the NO GO gage red member in the same manner The NO GO gage member may enter slightly into the die cavity but shall nat pass fully through the cavity If the NO GO gage member goes enter the cavity fully the die is warn and should be replaced GAGING DIMENSION GAGE CAUTION DO NOT CRIMP THE GAGE MEMBER MEMBER TQ DO SO MAY SERIOUSLY DAMAGE DIE FACE THE DIE SET PARTING LINE GENERAL INFORMATION TOUBLOSEDS The DANIELS HX4 crimp kaol features a system of interchonqgeahle dias There are already wide voriety of thes
118. ial shape The contact inserts are attached in the adapter Thus the screws attached to the contact inserts should be replaced by the M3 re taining screws included The original screws are too long to install in an adapter The coding elements 09 14 000 9908 9909 or 09 33 000 9908 9909 can be used to code the plug in connectors when you are using multiple connectors with the same mating profile Through holes with thread for installing the contact insert ai the knurled screw from the top section B Threads for interlock with captive good for multiple __ wx reuse for attaching the WE M3 retaining screws for adapter to the mounting contact insert wall Figure IV 36 7 Mounting cut out Figure IV 36 6 Screw adapter bulkhead mounting side bottom section Sie a ERN FN IV 64 IV Installation Instructions EE HARTING Product article number 09 00 000 5602 Description Screw adapter bulkhead mounting side bottom section Included in delivery Two screw adapters Imprint of the last four digits in the article number 5602 shown here Through holes unthreaded to hold the retaining screws for the corresponding contact insert Threads for interlock with the knurled screw from the top section P Figure IV 36 8 Screw adapter bulkhead mounting side bottom section Remarks The contact inserts should be mounted directly to the mounting
119. ices REACH compliance EU chemical regulation EC No 1907 2006 Business related certificates Quality management system in compliance with ISO 9001 2008 Environmental management in compliance with ISO 14001 RIS certification International Railway Industry Standard These certifications are updated in rotation A copy can be issued on request VII 4 VII Selected Standards Relevant to Railway Applications ee ooo HARTING CERTIFICATE DQS GmbH Deutsche Gesellschaft zur Zertifizierung von Managementsystemen heresy cerifies that the company HARTING Electronics GmbH amp Co KG hA riarnocrientraf D 32338 Espelkamp for the scope Cabling and Cabinets IRIS Scope 12 Design rmanufacturing and sales of industrial connectors kiona and POR connector caba assamblcs Fibreoptic systema and corngoncntiz his implemented and maintains a Quality Management System An audit documented in a report has vefed that the quality management system fulfills thet requirements af the falkwing standard International Railway Industry Standard IRIS Revision 01 November 2007 Carification audi 2000 03 21 Dertificatian decision J009 04 26 This certi cate is walid until 2012 04 25 Certificate Registration Mo 241243 IRIS Issued in Frankfurt am Main Germany 2006 04 26 IRISSS Certification D 51433 Fanki am Mai August crear Shree 21 VII 5 VII Selected Standards Relevant to Railway Applications re
120. in the module and you re ready to go Han Yellock is available in the following sizes Han Yellock 30 for 3 modules and Han Yellock 60 for 6 modules The flange seal around the circumference also covers the retaining covers and screws It ensures IP 67 protection in ac cordance with DIN EN 60 529 The wide range of coding possibilities also pro tects the connector from being inserted improperly An adapter frame for use together with the Han Modular series of modules is also available Vibration and shock resistance is ensured in compliance with EN 61 373 Figure lll 6 2 Figure lll 6 3 The Han Yellock hood Han Yellock and bulkhead mounting housing multiplying the potentials inside of the connector III 55 Ill Connectivity Products e HARTING III 7 Types of connections used in connectors HARTING connectors can be selected with a variety of wire connection types depending on the following factors Wire layout and type Availability of tools Installation location Location where connector will be used The wire connection methods used for railway applications include crimp cage clamp screw and axial screw connections All of these connections of fer a high degree of quality and reliability Additional information can be found in the catalogues Industrial Connectors Han Device Connectivity and Connectors DIN 41 612 IIl 56 III Connectivity Products eae
121. ing size 3 A eene 57 Achieving IP 65 or IP 68 protection degree for bulkhead mounting housings 58 Contact inserts with O ring seal 59 Han Brid contact inserts M eee eee eee KE k 60 Table of Contents IV 36 IV 37 IV 38 IV 39 IV 40 IV 4 1 IV 42 IV 43 VI 1 VI 2 VI 3 VI 4 VI 5 VI 6 VI 7 VI 8 VI 9 VII 1 HARTING Contact inserts with screw adapters 61 ET Wee E le esna sus 2 neyan kan Seven optatur ati M pe Du DAN BO ME 62 IV 90 2 Bottom SECON e 64 li DB dee 68 KEEN 72 IV 38 1 Coding with locking studs 72 IV 38 2 Coding with guide pins and guide sockets 73 Locking panel for locking lever 75 Han MTZ CMD EE 76 HARAX M12 L shielded eker ke k k kes 78 Han 3 A R J454 p0 amp uu a u an n b can on Quito ladan S W ley tUe e n RN 79 Han 3 A RJ45 8 pole and RJ Industrial RJ45 82 WET WORK SY E EE 2 Ethernet Switches for transportation 3 V 2 1 The Ha VIS eCon unmanaged switch 3 V 2 2 The Ha VIS
122. ing Cable gland Hood housing Pa Cover External Mounting PE connection plate Figure Ill 5 1 External construction Self locking clamp Cable with Han HC Modular connected shielding contacts Cable gland Distance bolt Cover Figure lll 5 2 Internal construction III 52 III Connectivity Products eae _ nT I 3 4 N T HARTING Table IIl 5 5 Technical details Contacts Han HC Modular 250 Han HC Modular 350 Han HC Modular 650 Support frame Stainless steel for holding contacts 3 or 4 contacts Han HC Modular 250 and Han HC Modular 350 3 contacts Han HC Modular 650 Cable gland Special cable gland with self clamping clip for contact with shield M25 or M32 Alternative Standard cable gland M25 or M32 IIl 53 Ill Connectivity Products S SSS HARTING Ill 6 Han Yellock housing and contact inserts Han Yellock is ideal for use in electrical cabinets and driver s console inside of railway wagons The totally new connec tor design offers a variety of innovative features in addition to an attractive new look These new functions include A new type of housing interlock mech anism on the interior Assembly with only one type of contact Multiplication of potentials from multi ple contacts carried out directly in the housing The structure of the Han Yel ock inter face consists of a device side bulkhead mounting housing
123. ing application illustrates the use of connectors that are based on HARTING housings from the Han B series Siemens Mobility has delivered a total of 70 Series 2016 Hercules diesel electric locomotives to the Austrian Federal Railway The connectors shown here enable a pluggable solution for power supplies and control data cables Because of the different space requirements the housings used here were fitted with the Han Easy Lock cross lever the Han Easy Lock lengthwise lever and the central locking lever for their interlock mechanisms These housings have naturally already been tested and verified for usage in railway vehicle applications Contact inserts can be chosen independently from the pluggable connec tion from the Han E Han EE Han DD Han Modular and Han K 6 6 series _ KA W Figure ll 9 1 Figure ll 9 2 Diesel locomotive for the Austrian Han B with central interlock mecha Federal Railway Hercules nism used for a current converter i LI di 4 yum j Figure ll 9 3 Figure ll 9 4 Han EE and Han ESS mounting Han B with Easy Lock lengthwise panel lever used on a generator II 10 Il Application Examples Eu HARTING Il 10 Sub floor container Sub floor containers are needed in order to supply voltage to the different functional units such as the lighting air conditioning or venti
124. ing grey M version Zinc die cast powder coating black IV 82 IV Installation Instructions E HARTING The assembly of the data module is identical for all variants Table IV 43 1 Contact assignments for the cable Ei II H mma MER TEBE l 3 J orange white green white Lp e poe ER Band 5 blue white blue white orange green pm m 8 bown bom GE Rear view of cable manager 1 IP 20 Data and Han 3 A Push the cable gland and housing over the cable insulating sheath HARTING Push Pull Gigalink IP 67 Adjust the all purpose seal so that it fits the diameter of the cable sheath in use Push the cable gland thrust washer all purpose seal and housing over the cable sheath c RJ Industrial RJ 45 IP 20 Han 3 A RJ45 2 Strip the sheath and the braid 40 42 mm 20 21mm 3 Cut 7 8 mm of the sheath and push it up to the end of the braid IV 83 IV Installation Instructions zan T TTT TT HARTING 47 50mm 7 8mm LN EE 5 Crimp the cable manager 800 0500 Be aware to insert the cable manager up to the end into the tool Attention Use only the HARTING RJ Industrial crimp tool part no 09 45 6 Cut the over standing ends of the wires in the way that no electrical short cuts are possible Excess end max 0 3 mm 7 Insert the cable manager into the data
125. ins Jeued dus Swel p alug Z 8 III 9 921 II 77 HARTING 8 LLL 86 8 LLL 001 pO 8801 Z 8E 8801 CZY 8801 cp S801 LE9 wu M U3pIAM 8101 Uo1g Hen ejduues jeje ww u 3u818H suoljeoijioads e91uu29 Ill Connectivity Products 133 v9 UEH 3 9Y UEH 83 3 d vc UeH OO 801 v9 elt 133 v9 UEH 3 9Y UEH 83 3 3 vc UeH OO 801 v9 UEH GEN Sulsnoy pooy J0 Suisnou Sununoul peau xnq s49 npojV UeH 104 Suisnou Sununoul peeu xinq oXeUINO UeH 104 4431y e Sulsnoy pooy J0 Suisnou Sul JUNOW peayy ng o4e NpPo UeH 104 Suisnou Sununou peau xnq s48 npojJ UeH 104 asesn Salag n z09G 000 00 60 U1IM U01 99UU09 ul luo MaJOS pue Jo91depe MaJos U1IM jaued dug jaued diuo awed Jd 9UJE4J pJerus SWE PIOUS SWE PIOUS uonduoseg xLL9S 0 00 60 L099 v cO 00 60 po 6046 000 00 60 S S 000 00 60 864G 000 00 60 LLZS 000 00 60 Jaquinu 9 911J8 1onpoJd III 78 Ill Connectivity Products HARTING senbaJ uo e qejreAe aie sdwejo pue sawed pjalys sjaued dius jeuonippy UJ09 3UI J8U SI 8U MMM 1e punoj 9Q ueo S 99US ejep SuipuodsaJJ00 aU E NN sdwe 9 LVS 000 00 60 n D O apis Sul junouj peeu nq 099 000 00 60 Jo1depe A 15S LL9S Z0 00 60 U1IM UOI129UuU00 ul luo epis 3U ZO9G 000 00 60 junoui peau nq Jaydepe M2J9S Jajawelp ejqeo WW 0 104 J8 9U18BI o qeo WW 103 or ez s ve cere I 8 qQq
126. is means that there are ten high current contacts in use for each connector Housing from the HPR 48 HPR series is then selected for the en closure This housing offers the advantage that it can be pre assembled and tested before the final assembly of the connector BOMBARHER H h GH Figure ll 3 1 Figure ll 3 2 Commuter tram vehicles in Frankfurt Entire view of motor connector mounted on vehicle Figure ll 3 3 Figure ll 3 4 Product photo Han 48 HPR hous Product photo contacts integrated ing motor connector in a support frame with cover IA Il Application Examples E HARTING Il 4 Connector for wagon couplings Connector modules from the Han Modular series are being used in the wag on couplings for the GTW 2 6 series from Bombardier Stadler The modules provide a pluggable solution for the following rail vehicle applications e Internal train bus MVB with the Han Quintax module four poles Low voltage supply and digital signals with the Han DD module Transmission of mid range power with the Han EE module Transmission of high power for batteries or climate control system with the Han 40 A Axial module e Video transmission via coax contacts with the Multi contact module Housings from the Han HPR series in size 24 B are used to provide reliable protection against environmental factors and adverse weathe
127. is prevents the wire strands from shearing off during the in stallation The wire ends do not need to be prepared in any special way other than merely stripping them Gs K P er TN i Wp Figure lll 7 1 Figure lll 7 2 Screw terminal Screw terminal with wire protection without wire protection There is no metal tongue on the screw terminals that have no wire protection Figure IIl 7 2 So wire ends must be fitted properly with wire end ferrules The following table lists the required tightening torque and testing torque for the screw terminals Table lll 7 2 Tightening and test torque for screw terminals Wire gauge mm I Nm Test moment of torque min pull out for stranded wire N with screws without heads III 58 Ill Connectivity Products o SOS HARTING Ill 7 2 Cage clamp terminal This connection method uses the force of a spring to clamp down the wire The advantage of this type of connection is that there is minimal operational overhead or tool work It offers a high level of functional reliability since the spring is constantly pressing on the contact DIN EN 60 999 specifies the re quirements for the construction and inspection of the spring terminals The advantages Use with solid and stranded wires e No need to process the wire ends in any special way e Strong clamping force applied as wire cross section increases e Wire connection is resistant to vibrations and shock e Cage
128. ission for the battery or air condition ing and the video signal transmission must be properly connected The connectivity solution must be pluggable because service technicians need to disconnect the cables during maintenance HARTING has designed and implemented a wagon to wagon cable assembly in cooperation with several of our railway customers We are a single source provider starting with CAD based design all the way to quality certified de VI 2 VI Customer Specific Solutions j r rima cc nr r rv HARTING livery The complete pre assembled and tested wagon to wagon cable solu tion includes the following e Connectors Cable glands System cable Protective cable tubes Mechanical hanger and strain relief in part with special lever systems e Stainless steel connector plate with strain relief mechanism Complete assembly Electrical inspection Suitable packaging for transport The wagon couplings on the interior and exterior of a train are subject to dif ferent requirements The requirements concerning water and dust protec tion for an interior installation are not as strict as for an exterior application Systems with IP 20 protection can be used for the wagon couplings used in wagon interiors but by keeping mechanical robustness of a IP 68 solution For exterior systems up to IP 68 protection is typically used UU e Figure VI 2 1 Figure VI 2 2 Total Inter Car Jumper Assembly Open HPR ho
129. l RJ45 Order numbers IP 20 09 45 151 15x0 IP 65 metal 09 45 115 15x0 Han A 09 45 115 15x2 Han M version Technical specifications for IP 20 RJ 45 connector acc to IEC 60 603 7 Number of contacts 8 Connector type Transmission performance Category 6 Class E up to 250 MHZ acc to ISO IEC 11 801 2002 EN 50 173 1 Transmission rate 10 100 1000 Mbit s Shielding fully shielded 360 shielding contact Mounting Field assembly Cable termination with piercing contacts Cable diameter stranded AWG 24 7 AWG 22 7 Cable outer diameter 6 1 mm 6 9 mm Mating cycles min 750 Degree of protection IP 20 Temperature range 40 C up to 70 C Housing material Polycarbonate UL 94 V0 Colour black UL approval E 102079 X 0 cable manager white 1 cable manager blue Technical specifications for IP 65 Han 3A connector RJ 45 Connector type Number of contacts 8 Transmission performance Category 6 Class E up to 250 MHZ acc to ISO IEC 11 801 2002 EN 50 173 1 Transmission rate 10 100 1000 Mbit s Shielding fully shielded 360 shielding contact Cable termination with piercing contacts Cable diameter stranded AWG 27 7 AWG 24 7 Cable outer diameter 6 0 mm 8 0 mm Degree of protection IP 65 IP 67 Temperature range 40 C upto 70 G Housing material Plastic version Polycarbonate UL 94 VO black Metal version Standard Zinc die cast powder coat
130. lator motors Modern sub floor containers have a modular design so that plug in connec tors can be used for connecting to the corresponding train components Since the containers are mounted under the floor the contact inserts must be reliably protected against environmental influences This is the reason that housings from the Han HPR series are used The following example shows a sub floor container for a CP 2000 train The Siemens Mobility Bombardier Transportation Consortium has delivered a total of 34 such trains to Portugal The sub floor container has been manu factured and tested by RWS Railway Service GmbH Contact inserts for both power transmission the Han K 6 6 and Han E and for control and bus data Han Modular are used to connect to the corresponding components Figure ll 10 1 The CP 2000 electric train E Dm T ade SUR Figure ll 10 2 Figure ll 10 3 Complete view of the sub floor Sub floor container back side with container the HARTING Han connectors Il 11 Il Application Examples 4 EE HARTING Il 11 Connectors in the electrical cabinet The central parts of the entire vehicle electronics and electrical system are installed within the electrical cabinets located inside of the railway vehicle Electrical cabinets have a pluggable design so that time and money can be saved during servicing and initial commissioning The pluggable design covers all areas from high current HARTING s Han
131. llation Instructions HARTING Installation in horizontal surface mounting housing 19 40 024 0931 3 x M25 for Han K 3 0 19 40 024 0971 3 x M25 1 x M20 for Han K 3 2 Han 24 HPR housings surface mounting angled EJE Han K3 0 F or K3 0 M Tightening torque 8 10 Nm please see catalogue information Z Aie n 4 E d Stripping length for Han K 3 0 straight version with Pflitsch UNI EMC cable gland type 254282008 for cable diameters 17 20 mm Shielding OD max 19 5 mm IV 14 IV Installation Instructions eg HARTING IV 4 Han HC Modular 350 Note The following instructions are valid for both the one pole and multi pole connectors Step 1 The diameter of the cable s outer insulation may not be greater than 19 5 mm strip the cable to the length of 19 mm Step 2 Guide the cable A through the hood B Step 3 Press the Han HC Contact C onto the end of the cable Hold the contact and cable end firmly in order to prevent twisting movement and torsion Use a torque wrench to apply the specified torque according to Table IV 2 2 All cable strands must be inserted completely into the contact chamber IV 15 IV Installation Instructions 9 _ Z f j j j j j j j jj lj j j j je n n j j j e zz j jk jhk jyj X rz rz HARTING Step 4 Put the support frame D into the hexagon shaped HC cont
132. lp meet these requirements As a result vehicle components are often manufactured at different sites and supplied by different contractors The individual components are then installed by the provider of the end system Modularity offers the advantage of accelerating the initial commissioning process It also significantly shortens the down time associated with maintenance and repair work Connectors can play a very important role in a modular design Because they can easily be plugged in and out connectors make it possible for electrical systems to be swapped out quite quickly The efficient Plug amp Play capability allows you to save time during commissioning or re commissioning The complex process of wiring up the connection cables is a thing of the past In the past few years HARTING has designed a product line more strongly aligned with the requirements of railway customers Product used in railway vehicles must also be fully railway compliant because they are exposed to very extreme conditions including temperature fluctuations moisture vibrations ballast strikes and electromagnetic radiation What significance does all this have for the product Robustness reliability and durability these are the key product requirements A complete line of tests are carried out to ensure that HARTING products are good enough to meet these strict requirements These tests are carried out by HARTING s own certified laboratory and are also
133. lt lt lt lt lt ttX 454 n HARTING IV 23 Installing the crimp flange and crimp sleeve for the InduCom housing Strip off the cable sheath on the bus cable strip about 35 to 40 mm de pending on the type of interface 2 Put the crimp sleeve over the cable sheath Bend the braided shielding over the cable sheath Cut off so that it overlaps the cable sheath by about 2 mm KZ 3 Guide the cable wires through the crimp flange Rotate the crimp flange gently under the braid until it reaches the cable sheath We recommend the special installation tool 61 03 600 0017 for this purpose 4 Position the crimp sleeve and then crimp using the hand crimper 61036000020 Apply the crimping jaws so they are as close as possible to the crimp flange 5 Iwist off the foil shield up to the crimp flange and then cut it off where it meets the flange Press the crimp flange into the housing 6 The wires should be stripped for 4 mm so they can be connected to the contacts in the connector Additional processing tips are described in the Device Connectivity Catalogue IV 44 IV Installation Instructions HARTING IV 24 Han Quintax 4 pole Vf pull back the shielding braid pull back the shielding braid CT Azo cable 3 6 cable O 3 6 cable 6 9 5 OF Gd Se able O 6 9 5 E 09 15 006 3013 09 15 004 3113 The pair must be aligned opposite each other in order
134. m o e 91jeuoqJeo jod 9jeuoqJeo jod 9jeuoqJeo od 9jeuoqJeo jod 9jeuoqJeo od 9jeuoqJeo Ajod 9jeuoqJeo od ojeuoqJeo jod 9jeuoqJeo od 91euoqJeo Ajod ejeuoqJeo od ojeuoqJeo jod 9jeuoqJeo od ojeuoqJeo jod 9jeuoqJeo od 91euoqJeo Ajod 9jeuoqJeo jod 9jeuoqJeo Ajod apiwedjod apiwedjod apiwedjod p we jod apiwedjod DEEN 9 hq 3 9 UeH IN S 9 UEH 2 H 3 9 UEH 9 4 3444 v9 UEH N 334 v9 YEH 9 4 3444 0 YEH 9 IN 333 Ok YEH 9 4 43 9v NYH 9 IN 33 97 NVH 9 4 44 Co NVH N 343 NVH 4J 33 81 NYH 9 IN 33 81 NYH 9 4 414 01 NYH 9 IN 33 0 NYH 29 Jt90 NVH 9 INT9Q NVH 29 J0v Q NVH 9 WOT Q NVH O Nd dS2 NVH O ILS dS2 NYH 29 f8 dSI NYH l1S QSI NYH 9 18 QZ NYH uondiosep 110uS 0Z 900 60 9192 900 60 09 900 60 LOLE 790 ZE 60 LOOE 790 60 LOLE OVO ZE 60 LOOE OVO 60 LOLE 910 60 LOOE 9v0 60 LOLE CEO ZE 60 L00 ZEO ZE 60 LOLE 810 ZE 60 LOOE 810 ZE 60 LOLE OLO ZE 60 LOOE 010 ZE 60 LOLE 790 LZ 60 LOOE 790 IZ 60 LOLE OVO LZ 60 LOOE OVO LZ 60 LOLE GZO LZ 60 L00 GZO 1c 60 LOLE SLO LZ 60 LOOE SLO LZ 60 LELE Z00 LZ 60 Jaquinu qed VII 13 HARTING 019144N OLSSNIG OA 610 asez sz zeng eoo jewuogeoKod WIWOSE 91 dWWY 001 4 9 9 1 NYH 019144N OLSSNIG OA 610 mg sz oo vezo euoqieoKod WWOS 91 dWV 001 1W 9 9 1 NYH 019144N 01SSNIG rein ner ez 1900 eco jeeuoqueofiod S 08 0 X NYH L0191
135. m the connection side The four screws for retaining the cover should be tightened with the specified torque IV 24 gets HARTING A IV Installation Instructions IV 11 Crimp contacts The following overview shows which crimping tools should be used for differ ent crimp contacts Table IV 11 1 Overview of crimping contacts and crimping tools d2 18duuri2 Crimping machine Crimping tool PAOWUAY t 6180 000 66 60 oBneb Bn g zFL80 000 66 60 ct E80 000 66 60 006 000 86 60 z006 000 86 60 L006 000 86 60 8E0 000 6660 2900 000 66 60 SCD 000 6660 Lon 000 66 60 1 55 1 80 1 55 X x 4 T009 000 86 60 L009 000 86 60 060 000 66 60 OSC 000 66 BO 20 000 66 60 COKO 000 66 60 x 1200 000 66 50 OL LO 000 66 60 L000 000 66 60 X x x x x x x 18 x 18 x 16 14 Power contacts 09 32 000 Han D Control contacts 09 15 000 0 75 1 0 1 5 2 5 IV 25 IV Installation Instructions 9 f i i i uu HARTING Han E Power contacts 09 33 000 09 99 000 0319 Coaxial DIN 41 652 T1 03 99 000 Locator 0508 Han C 09 99 000 0304 09 99 000 Locator 0311 Han D 09 99 000 0022 Locator Han E 1 The crimping machine TK base 09 99 000 6000 is required when op
136. mbly process is carried out without any screws or tools a simple click and mate snap in connection provides a reliable quick solution The locking levers can stay on the bulkhead mounting housing or be put on the hood as required When mated the locking levers protect the pegs from contamination A recessed area on the neck of the cable gland allows the connector to be labelled in a clear and simple manner III 17 Ill Connectivity Products HARTING Labeling Thermotransfer Hood Modular frame Gasket Housing bulkhead mounting Figure Ill 2 10 Overview of the Han Eco hood and housing III 18 Ill Connectivity Products HARTING 6B 10 B 16 B 24 B Figure lll 2 11 Sizes and dimensions III 19 II Connectivity Products HARTING III 2 8 Han B housing locking mechanisms The locking lever prevents the connector from being accidentally disconnect ed Several different interlock mechanisms are available for the Han B hood and housing series The type of locking most appropriate for use depends on your particular application Type of locking Product photo Two levers on housing Han Easy Lock two locking lever system One lever on housing Han Easy Lock one locking lever system Central lever aligned in middle on hood one central locking lever locking system Tw
137. ment class SR2 Dripping characteristic class ST 2 BS 6853 Smoke toxicity Classification Ib and II Oxygen index Classification la Ib and II CEN TS 45545 2 R23 for polycarbonate VII 7 VII Selected Standards Relevant to Railway Applications gai R no gt o Q L L N TT HARTING In regards to the connectors and network components provided by HARTING the flammable materials and the type of plastic used are the decisive fac tors in determining the reaction to fire The HARTING contact inserts and PCB connectors are mainly made from both polycarbonate and polyamide The total thermal fire load is based on the material dependent heating values together with the weight The most widely recognized fire protection standards as listed above spec ify so called small part formulas for such weight limits as 10 g or 50 g No special testing proof is needed for materials which only occur in minimal quantities and which do not exceed these quantities even when grouped to gether Since the precise formula and limit depends on the specific standard be sure to first speak with your sales representative in order to clarify the specifics In order to support the determination of the thermal fire load for individual projects a table has been compiled containing the high demand products This table contains the following information e Part number Short description Material Total weight Weight of flammable portion
138. mm Power trans mission Power trans mission Transmission of high power Ill Connectivity Products Current A Han Modular 63 Han Com 70 Han Modular Contact insert module contact accessory Han C module 3 pole 400 690 V Axial screw connection Crimp connection Han K 4 4 4 4 pole PE Power usage 63 A 690 V Control usage 16 A 230V Axial screw connection Caged tension spring connection Han 70 A module 2 pole 1000 V Axial screw connection Crimp connection Han K 4 2 4 2 pole PE Power usage 80A 830V Control usage 16 A 400 V Screw connection Han K 4 8 4 8 pole PE Power usage 80A 400 V Control usage 16 A 400 V Screw connection Han K 6 6 6 6 pole PE Power usage 100A 690V Control usage 16 A 400 V Axial screw connection for power Screw connection for controls Han K 8 0 8 polig PE 690 V Axial screw connection IIl 36 o aza Product photo Transmission of high power Combines power and signals in a single con nector Transmission Combines power and signals in a single con nector Combines power and signals in a single con nector Combines power and signals in a single con nector Transmission of high power Ill Connectivity Products Han Com Han Modular Han HC Modular Han HC Modular Han HC Modular Contact insert module contact accessory Han
139. mmended when installing the housings Recommended tightening Remarks torque Nm 0 8 1 0 0 8 1 0 0 8 1 0 Min 2 5 Min 3 0 0 8 1 0 Min 3 0 O ring Min 4 0 We recommend using the HARTING mounting frame when working with sur faces that have values which exceed the values specified above Table IV 33 1 Bulkhead mounting housing screw size torque Number of Series retaining screws Han 10A 16 A Han 15 EMC 25 EMC Han 32A M gt 2 z z 23 O CO o2 Es Han 32 B Han 48 B Han 3 HPR Han 6 10 16 24 HPR Han 48 HPR M Han w CO ON O1 IV 58 IV Installation Instructions gaza HARTING IV 34 Contact inserts with O ring seal A gasket is used to seal the plug in connector in the area between the top and bot tom sections for almost all housing sizes The gasket is mounted to the housing seal on the top section of housing for sizes 10 A and 16 A seal on the bottom section of housing for sizes 32 A 6 B 10 B 16 B 24 B 32 B and 48 B The only exception is for housing size 3 A Most of the contact inserts for this size have a seal on the male pin insert The following tables lists the details for the individual inserts Table IV 34 1 Overview of male contact inserts size Han 3A 09 20 003 2633 09 20 004 2633 09 36 008 2632 Han Q 2 0 09 12 002 2651 4 6 mm 09 12 002 2653 2 5 6 mm 09 12 002 2654 2 5 6 mm 09 12 005 263
140. n cooperation with railway system suppliers The goal was to design a pluggable solution for motors and drives with four high current contacts The hood and housing needed to have the same high quality and technical characteristics of the other HPR series in sizes 3 A 6 B 10 B 16 B and 24 B HARTING developed the Han 48 HPR hood and housing based on these requirements This housing series includes the hood surface mounting housing and bulkhead mounting housing The contacts and the contact inserts are mounted in a frame This frame is screwed onto the cover Then the complete unit is inserted into the corre sponding housing This assembly diagram is illustrated in Figure Ill 2 7 Note that there are two variants of the bulkhead mounting housing A version for installing high current contacts A version for installing contact inserts Han monobloc and Han Modular of size 16 B A protective cover is also available in this series that can be mounted onto bulkhead mounting housings and surface mounting housings The Han 48 HPR housings provide the excellent technical characteristics of all HPR housings and these additional advantages A varying number of high current contacts e A sample of available options 4 x Han HC Modular 350 5 x Han HC Modular 350 6 x Han HC Modular 350 10 x Han HC Modular 350 4 x Han HC Modular 650 4 x Han HC Modular 650 and 1 x Han HC Modular 350 Or alternatively 4contact inserts Han
141. n the crimp zone regularly Check the crimp zone of the tool for correct closing clean all moving parts These should move smoothly in operation Lubricate regularly Use machine oil SAE 20 Use with HARTING crimp contacts only Protect tool against high humidity and dust IV 39 IV Installation Instructions qoin C HARTING IV 21 Crimping tool 09 99 000 0248 This section includes the operation instructions for this crimping tools as well as an over view refer to Tab IV 20 1 listing the tools appropriate for the different types of DIN 41 612 crimp contacts These are the standard contacts also refer to the DIN 41 612 Connectors Catalogue Application field The crimp tool is designed for crimping of DIN 41612 crimp contacts 09020008434 8444 02050001512 and 2512 These are supplied in strips of appr 500 contacts per roll 2 The Roll Holder 1 caters for two wire crimp profiles thus guaranteeing easy handling with the best crimp result a Crimp profile 0 09 0 25 mm b Crimp profile 0 14 0 50 mm Each crimp profile crimps the contacts onto the conductors of the wire and the insulation in one step After the crimping process the contact is automatically cut from the carrier strip The wire then is easily removed from the tool with a successful crimp in 2 1 0 09 0 25 stalled onto the wire 0 14 0 50 mm mm Indexing Unit With aid of the Indexing Unit the 1 contact strip moves into the cor
142. nd as shown The No Go gauge may partially enter the indenter opening but must not pass completely through the opening Red Indenter wv Note The gauge will be delivered only on request Care of tool It is a good practice to keep indenter tips free of residual color band deposits and other debris A small wire brush may be used for this purpose We strongly recommend that you 1 Do not immerse tools in cleaning solution 2 Do not spray oil into tool to lubricate 3 Do not attempt to disassemble tool or make repairs This is a precision crimp tool and should be handled as such DMC offers complete refurbishing and recalibration services DMC specially engineers and manufactures complete tool kits to satisfy individual cus tomer requirements such as total aircraft support general shop maintenance or pro duction on board ship and vehicle service etc IV 37 IV Installation Instructions HARTING IV 20 Crimping tool for individual DIN contacts BC and FC 09 99 000 0620 The basic tool 09 99 000 0620 can be used with the following crimping insert sets Crimping insert set no For individual contacts Wire Isolation gauge mm mm vis Marking of the FC contacts is stamped on their rear side Locators are supplied with the crimping sets To order
143. nding assembled cables can also be ordered for the box Figure VI 4 1 MVB WTB Service Box Since the mid nineties the MVB has been used for the Fieldbus in vehicles manufactured by ABB Adtranz AEG Bombardier and Siemens The MVB con nects all key control mechanisms in the vehicle including drive controllers inputs outputs the driver s control displays decentralized door controls auxiliary inverters climate control systems centralized control devices and the train safety system VI 6 VI Customer Specific Solutions eee HARTING VI 5 Junction and distributor box The junction and distributor box shown below is offered by HARTING as a unit which is completely assembled wired and tested On the bulkhead mounting side this unit is already fitted with connectors for the different interfaces The junction and distributor box is completely wired up inside based on the project requirements Completely assembled cables can be used to plug into the unit The Plug and Play installation is thus significantly simplified and accelerated Figure VI 5 1 Stainless steel distributor box Heavy Duty Connectors and pre assembled D Sub cables VI 7 VI VI Customer Specific Solutions VI 6 Customized metal panel processing and electronic fittings The space for electronics onboard a train is quite limited The best use of this limited space must be determined in the planning and implementation phases of a project Sometim
144. net based The cameras and recording devices are connected to each other via Ethernet HARTING provides the system components for the network the switches connectors and system cable This example shows how the technology is implemented refurbished ICE 1 Figure ll 7 1 The high speed ICE 1 train Figure ll 7 2 The video monitoring layout eure Id HARTING products used in this application e left to right Ethernet Switch Ha VIS mCon 9080 B M12 connector DIN D20 plastic housing e D Sub full metal housing II 8 Il Application Examples HARTING Il 8 Stationary rail equipment In addition to our applications for moving railway vehicles HARTING com ponents are often used for stationary railway applications Figure Il 8 2 for example shows an axle counter mounted on a DIN rail Connectors may be used in control centres and heavy duty connectors may also be used for rail side electrical cabinets an These applications are often subject to test requirements similar to those for train applications such as those for vibration and temperature Special proofs may also be required for example to certify use in tunnels Figure ll 8 1 Figure ll 8 2 The axle counter system A detailed view of the axle counter system with DIN plastic housing Il 9 Il Application Examples 4 lt M HARTING Il 9 Connectors for use in interiors of railway vehicles The follow
145. ng housing Deag Module for two shielded Quintax contacts 4 or 8 pole Han Quintax module Only the 4 pole contacts are suitable for Ethernet Cat 5e and the transmission of CAN Bus MVB PROFIBUS etc 8 pole module 360 shielding Ethernet Cat 6A standard turned D Sub contacts Mechanically robust module Captive screws Han GigaBit module V 11 V Ethernet Networking Systems 3 6S HARTING V 3 System cable Figure V 3 1 M12 system cable The customer can choose from one of two options when using system cable Customers can order railway certified cable from HARTING in lengths from 20 to 500 metres The customer is then responsible for connector assembly For customers who prefer completely assembled and tested cable HARTING also offers system cable in a variety of lengths Customer specific lengths can also be provided on request The following variants with pre assembled connectors are available from HARTING M12 on both sides M12 Han 3 A RJ45 M12 HARTING RJ Industrial HARTING RJ Industrial HARTING RJ Industrial Additional variants are available on request Special cable assemblies intended for use in wagon couplings are also part of the HARTING product portfolio Such assemblies are produced in close co operation with the customer and in accordance with customer diagrams and any required testing HARTING is well positioned globally with ten different production
146. ng to DIN EN 60 228 VDE 0295 Class 5 Cable constructions that deviate should be checked separately IV 4 IV Installation Instructions HARTING GLY uoneo ipul 9 qeo 104 uo Isuauiip SI SS9291 uobexay eziS e v ve w x co cO Ja yaweip uone nsul o qeo xe zUJUJ GZ SIDEN zUJUJ 0L onbuJoj Buiu uBi L LJ Sc 0l 0 8 A UEH L L Sc OL S 9l 9 9 gt i SUEH L 9 M UEH cc 0l 9L V V gt l SUEH cc 0l co pojooejoud JeBul p p M sueH co 9l ewu BneB M y suj 5u Buiddins co o LO L N cO U0I 9 UUOI JIM EIXe pue s 19Sul JDEJUOI JO M8IAJ9AQ CC Al AGEL IV 5 IV Installation Instructions HARTING uoneo ipul o qeo 104 uo Isuauiip SI SS9291 uobexay zIS N Y lt r O tO tO Oo X OG Ja oweip uone nsul o qeo xe CN Jeuiu49 AA 19S EIXe YM ei npoui 2 gueH ejnpoui v OF UEL e npoui V OZ sUeH ejnpouuJ V 00l eUeH dd UM jnpow V 007 eSUEH ejnpouuJ V 00c eUeH dd Ui jnpow V 00c eSUEH ejnpouuJ V 00c eUeH eDeyoA YIH 0 z O eueH 0 Z O eUEH IV 6 IV Installation Instructions HARTING CZ dd Z 9 Jewog uoljeoipu 9 qeo 104 uo Isuauiip YSI Ol 2d CL 49MOg Ol dd S J9M0dq 1 uueIp SS9291 uone nsul uobexay ZIS age xe WN onbuJoj Buiu uBi L PEE EN c c c c C S8L OSL CL 0Z 04
147. nnected improperly DIN EN 60 204 1 VDE 0113 specifies that con nectors must be labelled clearly It recommends using a mechanical coding system to ensure that improper mating insertion is not possible HARTING offers coding elements listed in the following table for this purpose The In stallation Instructions and Tips Chapter describes the installation and gives an overview of the coding options Table lll 8 6 Coding elements Codingelements Locking stud for Han 6 coding options for housings with mono bena D one contact insert 09 30000 9901 two contact inserts Locking stud for 6 coding options for housings with Han Modular one contact insert Damme ft 09 14 000 99011 two contact inserts Guide pin for Han mono 16 coding options for housings with block contact inserts one contact insert 09 33 000 99082 15 coding options with two contact inserts Guide socket for Han 16 coding options for housings with mono EN inser P one contact insert 09 33 000 99092 15 coding options with two contact inserts Guide pin for Han mono With extended thread block contact inserts 09 33 000 99372 Guide socket for Han With extended thread mono a D 09 33 000 99382 Guide pin 16 coding options for housings with Han Modular one hinged frame 09 14 000 99082 15 coding options with two hinged frames Guide socket 16 coding options for housings with Han Modular one hinge
148. ns as an abutment and provides for a more secure mount to the wall The mounting frame is avail able for sizes 6 B 10 B 16 B and 24 B It is fitted with M4 threaded holes for the screws that attach it to the bulkhead mounting housing IV 54 IV Installation Instructions E HARTING When working with bulkhead mounting housings that do not have a rubber flange seal directly on the housing delivery status up to 2005 you must be sure that the flange seal is positioned precisely under the bulkhead mounting housing refer to Figure IV 30 3 Rubber flange seal with punched out holes for at tachment to the bulkhead mounting housing Retaining hole Figure IV 30 2 Bulkhead mounting housing until 2005 and rubber flange seal Figure IV 30 3 Bulkhead mounting housing until 2005 with mounted rubber flange seal The rubber flange seals both the self retaining and unattached versions are available as replacement parts If desired the unattached seal can be used with bulkhead mounting housings that are delivered with the self retaining seal However in this case be sure that both rubber flange seals are not used at the same time IV 55 IV Installation Instructions 9 HARTING IV 31 Han HPR housing sizes 6 B 24 B The bulkhead mounting housings from this
149. ntacts 22 Han HC Modular 350 and 650 high current contacts with screw COMICS TE 23 Installing the high current contacts in the Han 48 HPR housing series ii keke 24 GIMD COMOCIS ME m mr 25 Crimp contacts for wire cross sections from 10 to 240 mm 27 Buchanan four point crimping tool 09 99 000 0001 28 Hand crimping tool 09 99 000 0110 u E E 31 Crimping tool 09 99 000 0309 i cce REPE sukan kak a k n W a WA anak yan 32 Crimping tool 09 99 000 0374 E 33 Crimping tool 09 99 000 0977 lt y slniselksaskey rete du dana atc ew kun t 34 Crimping tool for coaxial contacts 09 99 000 0503 35 Crimping tools for D Sub contacts 09 99 000 0501 36 Crimping tool for individual DIN contacts BC and FC 09 99 000 0620 38 Crimping tool 09 99 000 0248 EE 40 Hand crimping tool 09 99 000 0191 42 Installing the crimp flange and crimp sleeve tor th Inducorm Bn Le TE TEE 44 Han Ouintax 4 pole EE 45 Han Ouintax 8 pole edu 46 Han E Re E 47 Hari E C 6001 EE 48 KEREN 49 Han 46 EE Multiplier a 52 Assembly notes for the Han B housing 54 Han HPR housing sizes 6 B 24 B tele 56 Han HPR hous
150. o levers on hood Han Easy Lock two locking lever system Table Ill 2 1 Overview of interlock types III 20 Ill Connectivity Products MM HARTING I1l 2 9 Han Easy Lock locking lever The Han B housing series comes with the Han Easy Lock in the default con figuration This clamp brings together a plastic grip and stainless steel spring It offers the following features Easy to operate Minimal operating force required Lever position can be set High number of usage cycles Resistant to corrosion Excellent sealing Tested against shock and vibration in accordance with EN 50155 Connector is easy and safe to handle even from hard to ac cess positions Rating components are made from thermoplastic self extinguishing in accor dance with UL94 VO Spring made from corrosion resistant steel Movable runner piece made from corrosion resistant steel Figure IIl 2 12 Han Easy Lock III 21 Ill Connectivity Products rponsnn n SSS HARTING Ill 2 10 InduCom hood 2 The InduCom line of full metal hoods is protected against radiated interference InduCom is suited for 9 pole to 50 pole D Sub connectors in accordance with Figure III 2 13 DIN 41 652 IEC 60 807 and MIL DTL 24 308 nduCom p They are predominantly used for bus systems KA 1 in industrial or railway applications SR These full metal hoods have up to four cable
151. o this safety record Two characteristics of flammable materials are very important in order to avoid personal injury 1 The materials must not be easily flammable so that it is not possible for fire to spread 2 The smoke from the burning material should as transparent as possible and contain as little poison as possible In the event of a fire this mini mizes the danger of asphyxiation and allows evacuation routes to remain visible standards primarily in Europe but also in the USA have established them selves and are now referenced throughout the world The standards with the strictest material requirements include BS 6853 DIN 5510 2 NF F 16 101 and NF F 16 102 The CEN TS 45545 2 2009 attempts to harmonize Euro pean fire protection standards Although the status until now has only been pre standard HARTING can already provide the first certifications for poly carbonate the most commonly used material According to CEN TS 45545 2 connectors are classified as non listed products and must comply at most with requirements class R23 e UL 94 Classification V O for polycarbonate and polyamide partially e NF F 16 101 Classification F1 I2 for polycarbonate Han NF F 16 102 and DIN D20 Plastic housing and special DIN rails ASIM E 662 01 Smoke density D1 5 amp D4 passed e Bombardier SMP 800 C The material complies with the requirements relating to toxic gas formation e DIN 5510 2 Flammability class S3 Smoke develop
152. ods with support panel VI 3 VI VI Customer Specific Solutions Livy A YT T Figure VI 2 3 Figure VI 2 4 Coupling between Wagon coupling mounted from the side below the wagons VK Figure VI 2 5 Wagon coupling installed on roof VI 4 VI Customer Specific Solutions se HARTING VI 3 Special housings Despite the wide variety of products in our catalogue special housing solu tions are often required to satisfy technical requirements or unusual instal lation situations These solutions include such modifications as additional drilled holes in existing housing special surface handling or new housing shapes Figure VI 3 1 Figure VI 3 2 Open housing in IP 20 Housing with custom drilled holes Figure VI 3 3 Housing with riveted PE earthing stud Figure VI 3 4 Housing with custom modification Figure VI 3 5 Multi distributor housing in IP 65 VI 5 VI Customer Specific Solutions 3 A HARTING VI 4 MVB WTB Service Box The Multifunction Vehicle Bus MVB is used as a Fieldbus for data exchange within a railway vehicle It is often used in conjunction with the Wire Train Bus WTB for data exchange throughout the entire train HARTING has developed the MVB WTB Service Box as a quick and easy solution for testing these communication networks and for switching them off during maintenance The Service Box is shown in the network topology as a T junction pick off The correspo
153. on per role ping tool mm 0 09 0 50 0 7 1 5 ull 09 02 000 8444 09990000248 0 09 0 14 28 20 0 25 0 50 009 028 07 15 FCI 09060007474 250 109990000247 0 14 0 25 28 24 0 14 0 25 0 14 0 56 0 8 2 0 09 06 000 7471 09990000119 0 37 0 56 26 20 0 50 1 30 0 50 1 50 1 6 2 8 FC3 09060007472 250 109990000120 1 00 1 50 20 16 IV 41 IV Installation Instructions qoin HBARTING IV 22 Hand crimping tool 09 99 000 0191 Crimping process Insert the contact into the locator Close the jaws slightly to lock the contact in place Insert the stripped stranded wire into the contact Complete the crimping operation Remove the crimped contact Adjustment of the eccentric ratchet plate If after prolonged use the crimp tensile strength in the connection between the stranded wire and the barrel of the contact is no longer sufficient the pressure of the jaws can be increased by adjusting the eccentric ratchet plate Undo two turns of the Phillips screw by means of a screw driver SW 2 mm Lift the toothed spring washer and turn it by hand counter clockwise in direction 9 Tighten the screw Pull out force and crimp quality has to be checked now again SCH Ouf force of the crimped wire at the connection is according to IEC 80352 part 2 Conductor cross section Pull out force mm AWG 0 14 26
154. or LE 41 80 for LOL gt 20 l4 far Lb 81 120 not classified a for LF gt 120 IIl 42 Ill Connectivity Products S SOS HARTING Classified in accordance with NF F 16 102 The tables from the NF F 16 102 show which flammability class and smoke factor class must be met in order to allow a product to be used in an ap plication with that group classification During the project tender phase the customer will specify which group must be implemented The classification scheme considers the type of train the type of route and the tunnels on the route The connectors classified as I2 and F1 an excellent classification for plas tics can be used for all four groups of railway applications according to DIN 41 612 IEC 60 603 2 Classification from NFF 16 102 April 1992 IIl 43 Ill Connectivity Products Table IIl 4 4 Overview of DIN 41 612 connectors with NFF classification F1 I2 DIN Signal 2B female connector with solder pins 4 5 mm AL 2 LM Qa ra D 22 232 6875 721 Lil 2C female connector with solder pins 4 5 mm PL 2 Six di Fe kora d Vc Za B female connector with soldier pins 4 5 mm PL 2 D 23 248 875 222 OF 02 264 49825 722 Li 4 nan C female connector with salder pans 4 5 mm PL 2 OF DJ 296 325 222 M female connector with solder pins 4 5 mm PL 2 order special contacts separately D
155. oved Table IV 17 1 Pullout forces according to DIN IEC 60352 2 A2 Conductor cross section _ force Han contacts We reserve the right to effect changes in design which may arise from improving the quality of our products new developments or because of changes in the manufactor ing process IV 34 IV Installation Instructions HARTING IV 18 Crimping tool for Coax contacts 09 99 000 0503 HOW TO USE THE DANIELS HX4 M22520 5 D1 CRIMP TOOL AND DIES DIE RAIL SLOT 4 GENERAL INFORMATION The DANIELS HX4 crimp tool is designed to crimp various sizes ond types of ferrules coaxial connectors contacts splices and terminal lugs to cables ond wires Interchangeable dies may be installed and locked in place with pins CAUTION BEFORE ATTEMPTING TO REMOVE DIES FROM TOOL ASSURE THAT ALL LOCK PINS HAVE BEEN REMOVED SEE FIGURE 4 FAILURE TO DO 50 MAY RESULT IN SERIOUS DAMAGE TO THE TOOL DI INSTALLATION 1 Align die roi slots in die halves with the roil in the crime toel and push shank of dies into holes Dies will snap inta place See Figure 1 2 Close koal handle to make sure dies ore properly seated The tool is now ready for use DIE RAIL DIE REMOVAL 1 with the crimp tool handle open ploce die remaval taol against end af knockout pin nnd top gently with small hammer See Figure 2 The die will be released from the front die holder It can now be removed by hand 2 Close t
156. owing number of requirements It is not always sufficient to rely only on the line of standardized products Instead there is an increasing demand for problem solvers tailored compo nents or systems that can fulfil custom requirements in a quick and reliable manner These systems are put together from standard components modifications and completely new innovations The customer specific solutions from HARTING can deliver simplified handling with initial commissioning tailored to customer needs They can also provide complex products and systems with integrated custom tailored de sign A wide range of engineering tasks are also taken into account during the product design phases We take advantage of our team of engineers professional graphic designers and our own high quality accredited laboratory so that we can deliver the best solutions for our customers Materials are also procured independently and in accordance with customer requirements This provides our customers with a level of flexibility that is extraordinary The most important requirement is to achieve outstanding quality and reli ability VI 2 Wagon to wagon cable assembly A variety of different data signal and power lines run through railway vehi cles The wagon couplings between rail vehicles are a vital component of this central nervous system A large number of components such as the internal MVB rail bus the low voltage power supply the power transm
157. r conditions No type of higher level protection against water and dust is needed However for wagon couplings that are mounted within the train and for interior instal lations a system with IP 20 protection is sufficient Modified hoods can be used here from the Han HPR series for some customer projects These are open on the sides and screwed directly onto the supporting wall using the riv eting nuts The bulkhead mounting housing on the bottom side is not needed so an added advantage is the resulting cost and weight savings Figure ll 4 1 The SLT train Nederlandse Spoorwegen igure ll 4 2 Figure ll 4 3 Model GTW 2 6 vehicles from the UBB Connectors on the wagon coupling Usedom Resort Railway Il 5 Il Application Examples 4 HARTING II 5 Connectors for control data and bus data in the driver s console For years Siemens Mobility has been delivering the B80D railway vehicles with their modern design and modular construction to Bursa in Turkey Even the control panel has a pluggable design and is constructed from mod ules A customized connector was designed to provide a pluggable solution for bus signals and control data in the control panel The Han Modular se ries with their Han Quintax modules for MVB and the Han DD module for control data are a good fit for this task In this case there is no need for housing since the connector is installed within the vehicle Knurled screws are used
158. reece Athens Greek State Railway OSE Netherlands Breda Viola Transport High speed trains Helsinki to St Petersburg Pendolino Deutsche Bahn DB ICE 1 2 3 Shinkansen E2 1000 Il 18 Ill Connectivity Products Chapter IIl Connectivity Products Table of Contents Il 1 Introduction 3 III 2 Hoods and housings overview essssseseessssserssssseeerssssseossssesersssssersess 4 Ill 2 1 Overview of Han hoods and housings and contact inserts 4 Ill 2 2 Installation location of the hoods and housings 6 Ill 2 2 1 Overview of housings and locations for industrial COMO CONS tee 6 Ill 2 2 2 Overview of products and locations for interface DIN Le el a ja gt eji bereede dee 8 Ill 2 3 Han HPR housing size 3 A long version 10 Ill 2 4 Han B hood with M50 cable entry 11 il 25 Han Easy Hood NEE 11 Ill 2 6 Han HPR and Han M hood and housin g 12 lll 2 6 1 Han 24 HPR enlarged hood and housing 13 lll 2 6 2 Han 48 HPR hood and housing 14 lll 2 6 3 Han 48 M hood and housing 16 Ill 2 7 Han Eco hood and housing a aa 17 Ill 2 8 Han B housing locking mechanisms
159. rent 6 A Signal contacts for cable Surface gold plated usage Wire cross section 0 09 1 5 mm Han D R15 contacts Rated current 10 A Cross section 0 14 2 5 mm Surface gold plated silver plated GoldTec Han E contacts Rated current 16 A Cross section 0 14 4 mm Surface gold plated Silver plated GoldTec Switching contacts silver plated 0 75 1 1 5 2 5 mm Han Yellock contacts Rated current 20A Cross section 0 14 4 mm Surface silver plated Han C contacts Rated current 40 A Cross section 1 5 10 mm Surface silver plated Refer to the Device Connectivity Catalogue for more details on the D Sub contacts Refer to the DIN 41 612 Connectors Catalogue for more details on the DIN contacts IIl 38 II Connectivity Products Han TC70 Han TC100 Han TC200 Han TC250 Han HC Modular 350 power contact PE contact Han HC Modular 650 Rated current 70 A Cross section 6 mm 10 mm 16 mm 25 mm For Han Modular Rated current 100A Cross section 10 mm 16 mm 25 mm 35 mm For Han Modular Rated current 200A Cross section 25 mm 35 mm 50 mm 70 mm For Han Modular Rated current 250A Cross section 35 mm 50 mm 70 mm For Han HC Modular 250 Rated current 350A Power contact Cross section 20 35 mm 35 70mm 95 120mm PE contact Cross section 35 70 mm For Han HPR and Han M housings size 48 Cross sec
160. reventing the accidental opening of the hinged frame when not installed Han Metal or plastic adapter Accessories Modular for the module carrier For the Han Quintax module In metal For a conductive connection between the housing and the shielding potentials Han Guide pins and sockets Accessories Modular for the D Sub module Han Multi contact module Data trans Modular 4 pole for Han coax mission contacts Crimp connection solder connection III 32 Ill Connectivity Products Han Modular Han Modular Han Modular Han Modular Han Modular Han Modular Contact insert module contact accessory Han Quintax module For holding the Han Coax and Han Quintax contacts 4 pole and 8 pole Han USB module USB 2 0 Connection via a patch cable Han D Sub module 9 pole 50 V Crimp connection Han GigaBit module 8 pole plus shield 50 V For Cat 6 Ethernet Crimp connection Han Quintax high density contact 8 pole plus shield 50 V Crimp connection Install in Han Quintax module Han D coax contact 1 pole plus shield For coax cable For Han D contacts Crimp connection Impedance 75 O Install in Han Quintax module Han Quintax contact 4 pole plus shield 50 V Crimp connection Install in Quintax module Han D 7 15 25 40 64 pole PE 250V Crimp connection Han DD 24 42 72 108 pole PE 250 V Crimp
161. rged III 41 Ill Connectivity Products s s HARTING II 4 3 Connectors in accordance with DIN 41 612 IEC 60 603 2 Trains are considered one of the safest modes of transportation throughout the world One factor that has contributed to this image of safety is the strict requirements restricting flammable materials used on trains The French NFF railway standard has established a widely recognized norm that is now used in many other parts of the world as well The HARTING connectors set a new benchmark they comply with DIN 41 612 and IEC 60 603 2 while also meeting the requirements of all hazard classes specified in NFF 16 101 and NFF 16 102 You can eliminate complex steps in the project planning phase when working with HARTING s DIN Signal and DIN Power connectors The approval process is also significantly simpli fied Classified in accordance with NF F 16 101 The NF F 16 101 is used to classify the flammability of non metallic materials used in railway vehicles The opacity and toxicity of the smoke and gas emit ted when the material burns are tested The following values control the way a connector is classified for usage Flammability class Smoke factor class for LO gt 70 and no inflammation at 960 C forLF amp 5 for LO 45 69 and no inflammation at 940 C for LF 6 20 for LO 32 44 F2 forLF 21 40 fer LO 23 31 and no afrerburning at amp 50 C F f
162. roducts designed to help customers reduce the strain and tension on shield PE connections We are also able to deliver customer specific solutions on request The following table Table Ill 8 7 is an overview of the products available in this area Dimensioning examples For Han monobloc inserts For Han Modular Clearance hole x CC PA NET E kel Sg M h IIl 76 HARTING wu M u1pIM e301 uoneJsnir ejduues jeje ww u 1u8 H suoljeoijioads e91uu29 Ill Connectivity Products a deus UPH Ys ay je Suisnou poou Sununoui peau nq ut adq ueH JJ U H oJ UEH 104 a deus ue SI 27 Zulsnoy pooy Sununoui peeu xnq ur dA sueH JJ U H oJ UEH 104 Suisnou Sununou peau xnq Ul s4e npo A UeH 104 as deus UE 14313y 27 Zulsnoy pooy Sununoui peeu nq ut adq ueH JJ U H oJ UEH 104 Suisnou Sununoui peeu xinq Ul sJe npojN UeH 104 gd eus UE 1U819U 27 Suisnou pooy Sununoui peau nq ut adq ueH JJ QUeH oJ UEH 104 Suisnou Sununoui peeu xinq Ul sJe npojN UeH 104 as deus UE 14313y 27 Suisnou poou Sununoui peeu nq ut QQ ueH JJ UeH 1 UEH 104 asesn Sellos E E B B B n E n m SWE p uS SWE PIOUS SWE PIOUS ou Plalys SWE pjerus AWE pl uS awed Plalys awed Plalys uonduoseq Jequinu e onJe 1onpoud Sdu ejo e depe ma
163. s 6 B 24 B not including 09 33 000 9991 with Han Modular size10 B e Vibration resistance in compliance with IEC 60 068 Part 2 6 e Shock and impact resistance in compliance with IEC 60 068 Part 2 27 e Can be used with the Han coding elements male guide pin and female guide socket e Retaining mechanism has high level of functional safety Not damaged when the recommended torque is slightly exceeded e Protection degree while plugged in according to DIN EN 60 529 IP 20 Additional information concerning these components can be found in the Han Industrial Connectors Catalogue IV 68 IV Installation Instructions HARTING Installation side Product article number 09 33 000 9984 Description Wall feed through metal Included in delivery Two Han Snap adapters die cast zinc We recommend always having a metal wall feed though when using the Han Snap components in railway vehicles This part was designed especially for railway applications and has excellent stability It can be used with standard contact inserts and Han Modular The schematic diagram included in this document details the proper mount ing cut out Figure IV 37 1 Wall feed through metal Figure IV 37 2 Schematic diagram of the mounting cut out Sz a c B 44 mm 36 mm IV 69 IV Installation Instructions 9 aoe HARTING Cable side Two variants are available for mounting the contact inserts to the
164. safe contact without the use of a grip panel IV 66 IV Installation Instructions sees HARTING The following overview describes the possible combinations for connections with grip panels and screw adapters Table IV 36 1 Combinations of grip panel with screw adapter screw adapter 09 00 024 5601 inserts size 24 B screw adapter 09 00 024 5601 inserts size 24 B IV 67 IV Installation Instructions DUBDD U D2K Qa IDIII EW 3 I zI ilI i8UlI DD J TI III oTf EWIIIDII g LIIaY UTHUOIII I IlFII lt I IeI lt i_ Z IICM MIIIOIIII lt IIIIIIII HARTING IV 37 Han Snap In addition to the screw adapters the Han Snap system also permits con nectors to be used without housings for interior railway applications such as in the electrical cabinet or in the driver s console The following table gives an overview of the components that may be used Table IV 37 1 Han Snap components suitable for use inside railway wagons Location Han Snap Product article Remarks components number Installation Wall feed 09 33 000 9984 Specially designed for side through metal use in railway wagons Cable side Coupling with 09 33 000 9991 the strain relief mechanism Cable side Plastic housing 09 33 006 0401 Size 6B 09 33010 0401 Size 10 B 09 330160401 Size 16 B 09 33 024 0401 Size 24 B The following is valid for all listed components e Suitable for standard contact inserts and Han Modular size
165. side 40 cable outlet for screw interlock InduCom housing With cable outlets straight or to the side for quick interlock InduCom housing With cable outlets straight or to the side for quick interlock MVB multi vehicle bus 360 shield connection Very space saving compact design Large space for wiring 360 shield connection Very space saving compact design Large space for wiring 360 shield connection Very space saving compact design Large space for wiring Quick locking mechanism 360 shield connection Very space saving compact design Large space for wiring Quick locking mechanism Interior of railway wagons Electrical cabi net distributor boxes contact of serial and parallel signals in bus application or interface ap plications Interior of railway wagons Electrical cabi net distributor boxes contact of serial and parallel signals in bus application or interface ap plications Interior of rail way wagons Electrical cabi net distributor boxes contact of serial and parallel signals in bus application or interface ap plications Interior of rail way wagons Electrical cabi net distributor boxes contact of serial and parallel signals in bus application or interface ap plications 2 WTB wire train bus III 25 Ill Connectivity Products HARTING III 2 11 Housing DIN 41 612 IEC 60 603 2 Table lIl 2
166. sites This permits us to produce locally and shorten the supply path Fisure V 3 2 Wagon coupling cable HPR version V 12 VI Customer Specific Solutions HARTING Chapter VI Customer Specific Solutions Table of Contents VI 1 Customer Specific Solutions 2 VI 2 Wagon to wagon cable assembly 2 V S Special MOUS eoi NETTE DE 5 VI 4 MVB WTB Service Box EE 6 VI 5 Junction and distributor DOX 7 VI 6 Customized metal panel processing and electronic fittings 8 VI 7 Interior Cabling for rail vehicles 9 VI 8 Connector sets and accessories 10 VI 9 Customized printed circuit boards 11 VI Customer Specific Solutions 3 s lt osss T _ Mp lt a gt M lt oaO b M HARTING VI 1 Customer Specific Solutions Modern railway vehicles have a more modular design and so are often manu factured in separate component assemblies at different locations Modern railway vehicles must also be outfitted and equipped for global use Vehicular solutions for customers must often be customized so that they comply with the gr
167. solution for the motors and drives used in railway wagons The outer dimensions of these hoods and housings correspond to the size of the 24 HPR They are designed exclusively for sup porting the Han HC Modular 350 or Han HC Modular 650 high current contacts In contrast to the other HPR hoods the hood stands 9 mm higher It has a total height of 120 mm Bulkhead mounting and surface mounting housings are available for mounting horizontally on the bottom section Spe cial support frames that only fit in this housing type are available for holding the high current contacts The following variants of support frames and housings are available Housing hood and surface mounting housing The variant with four high current contacts of type Han HC Modular 350 al lows you to fabricate pluggable connectors with three power connections Nor 2 2 Please note the following concerning this housing The bulkhead mounting housing must be ordered separately from the sur face mounting housing When using Han HC Modular contacts consider that the maximum cur rent load of each contact depends on the wire gauge e When using four Han HC zt Modular 350 a shrink sleeve must be pulled over the cable Figure lll 2 5 Prat Assembly principle Mb III 13 Ill Connectivity Products HARTING 11l 2 6 2 Han 48 HPR hood and housing Figure lll 2 6 Han 48 HPR This housing line was designed i
168. spJepuejg 612 0 N uonod jqewwe 1U8I9M anjeA Surjeau peo aif jeuu9u ES 83 fIN 9n eA SuneoaH L0 0 000 8000 O c o Q e eo E o Q 600 0 800 0 800 0 10070 900 0 610 0 100 610 0 v10 0 LO O LO O LO O LO O 610 0 v10 0 1Z0 0 810 0 Z0 0 Z0 0 L00 EI uonJod 9 qeuuelJ Jo 1ug19M L0 0 Z400 8100 6000 80070 80070 7000 900 0 S100 100 S100 v10 0 0 0 L 0 0 c 0 0 0 0 S100 v10 0 1200 810 0 FU U HA 070 O c o Q ban e o o e ojeuoqJeo od 91euoqJeo Ajod ajyeuoqueodfjod 9jeuoqJeo od 91jeuoqJeo Ajod 9jeuoqJeo od 91jeuoqJeo Ajod 9jeuoqJeo jod 9jeuoqJeo jod 9jeuoqJeo od 91euoqJeo jod 9jeuoqJeo od 9jeuoqJeo Ajod 9jeuoqJeo od 9jeuoqJeo Ajod 9jeuoqJeo od 9jeuoqJeo od 9jeuoqJeo jod 9jeuoqJeo jod 9jeuoqJeo od 91jeuoqJeo jod jersey v9 9 HS POW 9 UeH Vol S3 nq poy G ueH Vol S3 H5 poy S ueH 86931 5111317 XVO 2 ng GOW f NYH 911131 7 XVO 2 8 GOW 7 NYH XVO3 2 11S GOW t NYH ajewias GOW 1189310 UEL ajew GOW 492319 ULH Yor 2 8 GOW NYH vor 2 8 GOW NYH VOt 2 I1S GOW NYH VOt 2 I1S GOW NYH WWbO YOy S J poiN ueH YOY S 4 POW ueH WWbOL YOt s N poN UEL VOY S IN POW ueH XVLNINO 2 08 GOW v Z NYH XVLNINO ILS GOW v Z NYH ajewiay duu YOOL GOW Z UeH jew dwlu YOO GOW Z UeH zWWGZ 01 VOO S Nd GOW Z NYH zWWGE 91 VYOOL S Nd GOW Z NYH
169. ssivation Hood M25 straight screw interlock 19 40 003 0411 Angled bulkhead mounting housing with feed through holes 09 40 003 0951 Angled bulkhead mounting housing with M4 threaded tapped holes 09 40 003 0953 e Surface mounting housing M25 straight with feed through holes 19 40 003 0951 Surface mounting housing M25 with M4 threaded tapped holes 19 40 003 0953 Hood and Housing black powdered RoHS compliant Hood M25 straight screw interlock 19 40 703 0411 Angled bulkhead mounting housing with feed through holes 09 40 703 0951 Angled bulkhead mounting housing with M4 threaded tapped holes 09 40 703 0953 Surface mounting housing M25 straight with feed through holes 19 40 703 0951 Surface mounting housing M25 with M4 threaded tapped holes 19 40 703 0953 III 10 Ill Connectivity Products 9 HARTING IL3A Han B hood with M50 cable entry HARTING offers a Han B hood variant with a M50 cable entry In the past no cable gland larger than an M40 could be used with this housing series M50 cable glands can be used with the new hood This hood is available in a ver sion with a straight cable entry and a side entry for two lever locking on the housing It also comes with a side cable entry and a central lever The cable entry angle is 30 These hoods also feature a large cabling space and are fully compatible with all of the corresponding Han B hoods Figure lll 2 2 Han B III 2 5 Han Easy Hood
170. substantive laws shall apply exclusively The UN Convention on Con tracts for the International Sale of Goods CISG shall not apply General Notes _ LL HARTING Standards and other technical regulations The standards directives and other technical regulations cited in this docu ment refer to the current editions available at the editorial deadline Only the most current standard however is authoritative for the user of that standard Table of Contents 4 HARTING Table of Contents I 1 EO OT MT 1 ee HOW S mmm 2 Il 2 Integrating connectors into the design phase of railway vehicles 3 l 3 Motor ein Le EE 4 IL 4 Connector for wagon couplings 5 Il 5 Connectors for control data and bus data in the driver s console 6 l 6 Rotary LEE 7 l 7 Da a COMMUNICATION sso w aa Dm E EDI DNO taverns 8 ll 8 Stationary rail equipment 9 IL 9 Connectors for use in interiors of railway vehicles 10 ll 10 Sub floor container 11 ll 11 Connectors in the electrical cabinet 12 Il 12 Controlling pantographs 13 Il 13 Connectors used in the coupling area of railway vehicles 1
171. t insert Figure IV 29 4 Han 46 EE multiplier retention The completely assembled Han 46 EE multiplier Figure IV 29 5 Han 46 EE multiplier assembled IV 53 IV Installation Instructions 9 HARTING IV 30 Assembly notes for the Han B housing Several issues must be kept in mind while assembling the bulkhead mounting housing In order to reach the IP 65 degree of protection the bulkhead mounting housings are delivered with a rubber flange seal This seal is the same size as the bulkhead mounting housing refer to Figure IV 30 1 The rubber flange seal grips the housing and also prevents the retaining screws from coming out This helps to speed up the add on and installation procedures The holes for the retaining screws are located in the sealing area In order to create a reliable seal be sure to follow these points Protuberance to fit into the retaining hole on bulkhead mount ing housing Ba Retaining hole Figure IV 30 1 Bulkhead mounting housing with rubber flange seal e n order to prevent humidity from penetrating through the M4 retaining screws into the housing the customer must take steps to seal this area e f you are installing on metal panel walls you can install a mounting frame on the opposite side of the wall This frame functio
172. tages of the crimp connection method are Can be processed with crimping machines or with manual crimping tools e Connection are produced efficiently Crimp quality is consistently high when the tools are used properly Nochange in resistance as result of heat Wire under the crimp connection remains flexible The test of a good crimp connection is the wire pull out force This force is specified in DIN IEC 60 352 2 for wires with cross sections up to 10 mm These specified pull out forces for the crimp contacts are maintained when HARTING crimping tools are used in a proper fashion The wire pull out forc es are listed in the following table VDE 0220 is valid for crimp connections of wire cross sections greater than 10 mm Table Ill 7 3 Pull out forces for crimp connections in accordance with DIN IEC 60 352 2 A2 Pull out force luere E e HARTING contacts O N 18 Han D Han E D Sub DIN 41 612 28 _ HanD Han E D Sub DIN 41 612 32 Han D Han E D Sub DIN 41 612 An Han D Han E D Sub DIN 41 612 60 Han D Han E D Sub DIN 41 612 85 Han D Han E D Sub DIN 41 612 r 90 Han D Han E DIN 41 612 Han D Han E DIN 41 612 Han D Han E DIN 41 612 Han D Han E DIN 41 612 200 Han D Han E Han C 230 HanD Han E Han C 33 12 275 HaEShc c 40 310 Lennart 600 10 30 nent 1000 8 380 jHnc S
173. tal down behind the locking lever tongue is sitting completely under the grip of the locking lever 3 The metal tongue is now pressing 4 In order to release the connection you must under the grip and thus preventing press on the metal tongue with a screwdriver the lever from opening This allows the locking clamp to glide over the metal tongue and release the connection IV 75 IV Installation Instructions IV 40 Han M12 Crimp Order number 21 03 882 1405 Technical details leo N j HARTING Male contact Female contact Conductor cross section 6103 000 0073 61030000074 0 34 0 5 mm AWG 22 20 Recommended crimping tool Locator Wire diameter Cable outside diameter Seal transparent Seal light grey Degree of protection Rated voltage Rated current Working temperature Temperature during connection Mating cycles Recommended tightening torque mating side Coding Cable stripping length female Cable stripping length male 61 03 600 0022 61 03 600 0023 2 0 2 3 mm 4 5 5 4 mm 7 0 8 8 mm IP 67 50V 4A 40 C 85 C 5 C 50 C gt 500x 0 5 Nm D A 17 20mm 20 23mm 1 Please respect the manufacturer s recommendations 2 t is the user s responsibility to determine the correct outer jacket stripping length for each cable and connector combination used Ideally this should be in the range of 17 to 20 mm for female and 20 to 23 mm for male connec
174. them separately use the following part no 09 99 000 0631 locator FC1 Set up Crimping inserts e Screw off the fixing screw 1 pliers closed Close tool until it releases now open the tool Remove inserts first upper part Install new inserts marking 2 has to have same colour first insert lower part Fix the screws again with ISKA M4x18 upper ISKA M4x9 lower Plug the locator from the top in a 90 posi tion as shown in the picture IV 38 IV Installation Instructions 4 MM HARTING Safety ratchet he hand crimp tool can only be used after it has been opened completely Each crimp pro cess has to be done fully before the tool can be opened again This guarantees a good quality crimp each time Do not open or close the tool by force Early crimp unclamp It is possible to open the tool during crimping if necessary Slightly hold together the grips of the tool Open the safety barrier on the rear side of the tool by turning left or right Open the grips of the tool to release the partial ly crimped contact Crimp process Fold up locator Assemble the contact into the locator select the right chamber Fold back the locator Close the tool until the contact is held Put the wire into the crimp opening Crimp the contact until the tool can be released Take out the crimped contact Maintenance Remove any existing material and dirt and clea
175. thods the current 2004 edition of the standard de scribes only the solder free wrapped connection IEC 60351 1 and the crimp connection IEC 60352 2 Special specifications are given for solder connec tions If other wire connection methods are in use for example IDC these methods must first be clarified with the user A European standard specifically for railway vehicle connectors is in the draft approval stage It is entitled prEN 50467 2009 Railway applications ve hicles electrical connectors provisions and testing processes This draft standard covers many more wire connection method variants than the EN 50155 For example these extensions are included IDC insulation displace ment connection cage clamp and press in Compared to EN 50155 there are more details distinguishing the testing requirements for connectors de pending on the installation location VII 3 VII Selected Standards Relevant to Railway Applications 3 Si HARTING VII 1 3 Additional standards Selected standards referenced from the EN 50155 Shock and vibration EN 61373 Category 1b by default Category 2 on request Environmental testing IEC 60068 Electromagnetic compatibility EMC EN 50121 EN 61000 4 4 Country specific certificates CCC China Compulsory Product Certification GOST certification Russia RoHS compliance EU directive for restricting the use of certain hazardous materials in electri cal and electronic dev
176. ting housings It is used to seal between the housing and the mounting surface Gasket Required for all housings bulkhead mounting surface mounting and coupling housing types It ensures the proper seal between the top and bot tom housing sections O ring seal Used for Han HPR and Han EMC B housing series It is posi tioned at the housing overlay and at the sealed area between the hood and housing III 87 III Connectivity Products ey HARTING Notes III 88 IV Installation Instructions HARTING Chapter IV Installation Instructions Table of Contents IV 1 Metal eet NSt uUGHONS TD 3 IV 2 Contact inserts with axial screw wire connection 4 IV 3 General installation information for contacts in the axial screw connection 9 IV 4 Hanh HC Modular 350 keke breve d heure 15 WS Ha eege TEE 17 IV 6 Installation instructions for the Han 24 HPR enlarged holder 19 IV 7 Coding options for the Han HC Modular contacts 20 IV 8 Doubled contacting with axial screw contacts 22 IV 9 Han HC Modular 350 and 650 high current contacts with screw ees seio TE 23 IV 10 Installing the high current contacts in the Han 48 HPR HOUSING Sel r S ENNIO TT 24 SIE REENEN 25 IV 12 Crimp contacts for wire cross sections from 10 to
177. tion 35 mm 50 mm 70mm 95 mm 120 mm For Han HC Modular 350 Rated current 650A Cross section 70 120 mm 150 185 mm For HPR housing Cross section 240 mm For Han HC Modular 650 HARTING Axial screw Product Features Connection type Product photo Screw connec tion method for cable lugs up to 120 mm only install in bulkhead mounting housing Crimp Axial screw Screw connec tion method for cable lugs from 70 to 240 mm only install in bulkhead mount ing housing Crimp III 39 III Connectivity Products ey HARTING Table IIl 4 3 Overview of support frames for the Han HC Modular contacts Product illustration Housing Han HPR size 4 x Han HC Modular 250 1 x Han HC Modular 350 2 x Han HC Modular 350 2 x Han HC Modular 350 3 x Han HC Modular 350 3 x Han HC Modular 350 ga 1x PE K W r Han M housing Size 48 B 1 x Han HC Modular 650 2 x Han HC Modular 650 4 x Han HC Modular 350 2xQ5 0 III 40 III Connectivity Products eae Rage Product illustration Housing Han HPR size 4 x Han HC Modular 350 a 1x PE x 48 B E i 6 x Han HC Modular 350 48 B 10 x Han HC Modular 350 For holding 4 contact inserts and or 4 hinged frames Han Modular size 16 B 3 x Han HC Modular 350 24 HPR enlarged 3 x Han HC Modular 650 24 HPR enlarged 4 x Han HC Modular 350 Delivered with shrink sleeve LI 24 HPR enla
178. to implement a reliable Ethernet connection in accordance with ISO IEC 11801 Category 5 Dimensions in mm IV 45 IV Installation Instructions 9 e j j j e __m bp r oo e7 Zv rgz HARTING IV 25 Han Quintax 8 pole cable O 3 6 cable O 6 9 5 09 15 008 3013 09 15 008 3113 Dimensions in mm IV 46 IV Installation Instructions Ce HARTING IV 26 Han D Coax pull back the shielding braid pull back the shielding braid D 4 Bee cable 3 6 cable 3 6 cable 6 9 5 f cable 6 9 5 09 15 001 3013 09 15 001 3113 Dimensions in mm IV 47 IV Installation Instructions qoin HARTING IV 27 Han E Coax KXXXXXXXXXX 2919 9 9 9 9 9 9 9 9 7 5 23 23 Ze EN j lt lt _j KXR crimp contact cable 6 95 cable 3 6 cable 3 6 cable 6 9 5 09 15 001 3023 09 15 001 3123 Dimensions in mm IV 48 IV Installation Instructions EE HARTING IV 28 Han GigaBit Module Strip wire to the correct length and move crimp ferrule over the cable sheath TEE C ag zm Sa mai xa Pull back the shield to the correct length and strip the wire IV 49 IV Installation Instructions HARTING Check the contact positions and take care that the shield ends right behind the plastic insulator HALT ORS Narr IM MARTNG
179. tors The A coded variant can also be used for 110 VDC power supplies Other D Sub contacts may be used in addition to the specified D Sub contacts The following are typical for railway applications 61 03 000 0112 male AWG 18 22 0 34 0 75mm 61 03 000 0113 female AWG 18 22 0 34 0 75mm 09 67 000 8672 female AWG 18 22 extra robust D Sub female contact 09 67 000 3476 female AWG 18 22 0 34 0 75mm 09 67 000 3576 male AWG 18 22 0 34 0 75bmm IV 76 IV Installation Instructions 9 p 2 r fi a B Ju k j T STE HARTING Remove cable jacket and strip cores Twist screen ing braid as shown and crimp contacts Slide screw cap ring and seal onto the cable Push screening braid into the seal slot Insert contacts into lo cator from the side Fix contacts with the aid of assembly aid Slide loca tor into connector pay attention to the coding 4 Seal has to be flush with connector Slide ring over the seal and cut off screening braid 5 Tighten screw cap Remove assembly aid o o1 2 3 4 The seal has to be replaced when worn IV 77 IV Installation Instructions P HARTING IV 41 HARAX M12 L shielded The HARAX M12 connectors have been designed and tested according to the IEC 60352 4 and IEC 61076
180. ut the wire strands with the contact on the con nection side Han E 09 99 000 0319 Opens the contact cavity and pulls out the wire strands with the crimped on contact on the connection side Han C 09 99 000 0305 Opens the contact cavity and pulls out the wire strands with the crimped on contact on the connection side Removal tool for remov ing the Quintax con tacts from the Quintax module Han Quintax 09 99 000 0323 D Sub contacts 09 99 000 0511 Assembly and removal tool Coaxial contacts 09 99 000 0512 Removal disassembly tool BC contacts Removal disassembly 09 99 000 0101 FC1 FC2 and FC3 contacts 09 99 000 0087 tool Removal disassembly tool III 1 Ill Connectivity Products _ c _ lt _ rr zczc jj Ss HARTING Table Ill 8 4 Assembly tools Features Product photo Assembly tools Assembly tool for Recommended for wire crimp contacts cross sections less than 0999 0000059 0 75 mm AWG 18 For Han D and Han E contacts stripping tool For stranded 09 99 000 0159 and solid wires 0 08 10 mm AWG 28 AWG 6 Allen hex wrench for axial terminal screw For 09 99 000 0313 40 A contacts SW 2 09 99 000 0363 100 A contacts SW 4 09 99 000 0364 200 A contacts SW 5 09 99 000 0364 350 A contacts SW 5 09 99 000 0365 650 A contacts T 8 3 8 adapter 09 99 000 0370 100 A contacts SW A 09 99 000 0371 200 A contacts
181. wall since the corresponding through holes are unthreaded The adapter is not secured by the contact insert Thus during disassembly it is important that you do not lose the adapter The version 09 00 000 5603 should be used for current projects Standard contact inserts EDE 6B 48 mm mm __6B__J 35 mm 44 mm 52 mm 94 mm Figure IV 36 9 Mounting cut out IV 65 IV Installation Instructions P E HARTING The screw adapters for the top and bottom section are designed so that when used together with the grip panel the proper gap between the male and female inserts is automatically maintained which ensures that the con tacts are properly inserted The gap is also automatically set during the installation of the housings The gap as measured between the contact support surfaces of the contact inserts must be between 19 5 mm and 21 mm Gap for reliable electrical contacts 19 5 21 0 mm Figure IV 36 10 Screw adapter with grip panel When maintaining these safe contact dimensions 19 5 21 0 mm while us ing screw adapters without a grip panel galvanized steel spacer washers 4 x 8 x 0 8 according to DIN EN 28378 previously DIN 1440 should be used on the cable side When plugged in these ensure that the proper gap is main tained between the top and bottom sections refer to Figure IV 36 11 Figure IV 36 11 Spacer washers for creating the Screw adapter without grip panel required gap to ensure a
182. your technician whether in production or when install ing on site This is particularly significant for Fieldbus systems because they have many slave interfaces The following graph shows the shielding attenuation behaviour for HARTING s InduCom connectors 5hiclding eff ninan af BE hada w BEV 0 Sart hoa Serge E z 4 AF HA pral n p EC ioe D pred We nac i L A eem 382 ope k shielding eltelaney a d F E a T s L TU IM apes Sp dik drett Takt Figure IIl 2 16 Attenuation graph for the InduCom ira prey Ela The labyrinth design of the InduCom 9 housing combined with the crimp flange provide for excellent EMC characteristics and a shield attenuation of greater than 60 dB up to 500 MHz In order to achieve this level the entire shielding braid 360 is connected to the housing using the optimal com bination of crimp flange sleeve and crimping tool to form the perfect low resistant connection Figure IIl 2 17 Figure IIl 2 18 Crimp flange InduCom full metal hoods With full surface contact III 23 Ill Connectivity Products Table Ill 2 2 Overview of InduCom hood Product Features Area of use Product photo InduCom9 MVB connector set InduCom9 WTB connector set InduCom9 CAN connector set InduCom9 Profibus connector set InduCom9 housing With straight cable outlets Cage tension spring conne
183. ystem 17 Ee Oe RE e 18 Il Application Examples HARTING ll 1 Overview Several typical railway applications that make use of HARTING products are described in this section Sub systems such as current converter and Electrical f Wagon couplings climate control devices cabinet wiring Driver s console Passenger information data communication yt and sensor systems Motor drive d s e d e oF Network systems Figure Il 1 1 Overview Il Application Examples S ISOS HARTING Il 2 Integrating connectors into the design phase of railway vehicles All HARTING connectors and housings have been tested and approved for use in railway vehicles A distinction must be made based on where the con nector will be used on the vehicle Housings with the Han Easy Lock locking lever Han B and Han EMC B series are intended for unrestricted use within vehicle interiors The user friendly Han Easy Lock locking lever requires only a minimal amount of force when moving it When planning for exterior vehicular use however this feature would not be desired or beneficial Outside events such as snow gravel and stones strikes or vandalism present a risk that the lever could be opened unintentionally which could lead to a vehicle malfunction Housings intended for outside use are fitted with a screw interlock mecha nism the HPR series in order to pr

HARTING User's Guide Transportation - HARTING

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