RockStar® inserts
HSB series – the heavy-duty connectors
HSB series – the heavy-duty connectors
The HSB series provides users with 35 A via each contact with screw connections for a safe and reliable connection.
B
Technical data
Approvals Inserts No. of poles Rated voltage Rated voltage to UL/CSA Rated current Rated impulse withstand voltage Pollution severity Insulation resistance Material Temperature range Flammability to UL 94 Mechanical service life – Plugging cycles Ag - Surface – Plugging cycles Au - Surface Contact resistance Screw connection Contacts / Material Sockets and plug-in contact Surface Screw connection – Clamping range
Derating curves DIN EN 61984 DIN EN 60664-1 UL/CSA
80
6, 12 400 V 600 V 35 A 6 kV 3 ≥ 1010 Ω Glass-fibre reinforced PC (in UL list and approved for railway applications) –40 °C ... +125 °C V–0
70 60
Basic curve
50 Derating curve
40 30 20 10 0 0
≥ 500 ≥ 500 ≤ 2 mΩ Copper alloy Passivated silver 0.5 – 6 mm2 (AWG 20 … 10)
– Stripping length – flex. with wire end ferrule acc. to – DIN 46228 Part 1 Clamping torque
11 mm
– Screw connection SD blades PE connection – Clamping range
1.2 … 1.5 Nm 0.6 x 3.5 or 0.8 x 4 mm
4 mm2
0.5 … 6 mm2
– solid / stranded – flexible / flexible with wire end ferrule, DIN 46228 pt. 1 – AWG conductor – Stripping length
0.5 … 6 mm2 / 0.5 … 6 mm2
– Clamping torque – Blade dimensions
2 … 2.5 Nm SD 1 x 5.5 mm or PH 2
0.5 … 6 mm2 / 0.5 … 6 mm2 AWG 20 .. 12 10 mm
Note: When used properly and as designated, the listed connectors may not be connected or disconnected if there is a live voltage or load! When connecting flexible conductor with a screw connection, you should use ferrules, according to DIN 46228, section 1.
B.88
2 x HDC-HS-B6S(B)S with H07V-K6 encapsulated
90
Amperage A
Standards / approvals Standards
10
20 30 40 50 60 70 80 90 100 110 120 130 Ambient temperature / °C Verified operating range up to max. 35 A (upper limit current)
RockStar® inserts
HSB series – the heavy-duty connectors
B
Overview Size
Rated voltage
Rated current
No. of poles
Tension clamp connection
Screw conn. with wire guard spring
Crimp Push In connection
Axial screw connection
Page
6
400 V
35 A
6+h
•
B.90
10
400 V
35 A
12 + h
•
B.92
B.89
400 V, 35 A, Size 6 6+h Inserts Screw connection Designation HDC HSB 6 MS
Order No. 1498700000
Dimensions
Female
HDC HSB 6 FS
1498900000
Male
84.5
77.5
34
34
19
Insert Male
19.5 – 21.0
RockStar® inserts
HSB series - the heavy-duty connectors
27
16.5
3214
35.5
B
Female
Arrangement of contacts Male
3222
Female
3230
Mounting cut-out
17
27
36
77.5
M3
71 84.5
3238
B.90
RockStar® inserts
HSB series - the heavy-duty connectors
Selection of Housings RockStar® IP65 / IP66 Size 6 For additional housings, refer to Chapter D.
Hood Plug housing, cable entry sideways Version Cover b (mm) w. threading without cover 61
Designation HDC 16B TSBU 1M25G
Order No. 1788180000
M25 M32
w. threading without cover 76 w. threading without cover 76
HDC 40D TSBU 1M25G HDC 40D TSBU 1M32G
1787010000 1787000000
45.5 a b
a M25
93.3
59
a
45.5
B
Plug housing, cable entry at top Version Cover b (mm) w. threading without cover 61
Designation HDC 16B TOBU 1M25G
Order No. 1788210000
M25 M32
w. threading without cover 76 w. threading without cover 76
HDC 40D TOBU 1M25G HDC 40D TOBU 1M32G
1787070000 1787060000 b
a M25
59
93.3
Cover Designation HDC 16B DMDQ 2QB
Order No. 1665270000 18 34
Version For hoods
93.3 136.2
55
43
Base Bulkhead housing Designation HDC 16B ABU
Order No. 1208600000
136.2
b
Cover b (mm) without cover 29
55
5.25
Version
Ø4.5
93.3 103 115
32 43 47
Base housing Version
Designation
Order No.
M25
w. threading without cover 64
Cover
b (mm)
HDC 16B SBU 2M25G
1788240000
M25 M32
w. threading without cover 84 w. threading without cover 84
HDC 40D SBU 2M25G HDC 40D SBU 2M32G
1787120000 1787110000
55
136
5
a
a
b
a
Ø5.5
93.3 105 117
45 56.5
Coupling housing Version Cover b (mm) w. threading without cover 79 w. threading without cover 79
Designation HDC 40D KBU 1M25G HDC 40D KBU 1M32G
Order No. 1787200000 1787190000
136.2
55
b
a M25 M32
a 45.5 93.3
Cover Designation HDC 16B DODQ 4BO
Order No. 1665260000
93.3
7 17
Version For bases
43 58.5
B.91
400 V, 35 A, Size 10 12 + h Inserts Screw connection
HDC HSB 6 FS HDC HSB 6 MS 7 - 12 HDC HSB 6 FS 7 - 12
1498900000 1498800000 1499000000
Male
34
84.5
19
Female Male Female
Dimensions
34
Order No. 1498700000
27
77.5
16.5
3272
Designation HDC HSB 6 MS
35.5
B
Insert Male
19.5 – 21.0
Female
Arrangement of contacts Male
3280
Female
3288
Mounting cut-out 77.5
17
35
27
M3
71 84.5
3296
B.92
71
RockStar® inserts
HSB series - the heavy-duty connectors
RockStar® inserts
HSB series - the heavy-duty connectors
Selection of Housings RockStar® IP65 / IP66 Size 10 For additional housings, refer to Chapter D.
Hood Plug housing, cable entry sideways a M32
Version Cover b (mm) w. threading without cover 79
Designation HDC 32B TSLU 1M32G
Order No. 1788420000 b
a
98 108.5
82.5
B
Base Bulkhead housing Version
Cover with cover
b (mm) 55
Order No. 1219800000
HDC 32B ALU
1219500000
109.5
94 110 126
Ø5.5
b
without cover 38
Designation HDC 32B ADLU
31
65 82.5 89
23.3
Base housing Version Cover b (mm) w. threading with cover 96 w. threading without cover 79
Designation HDC 32B SDLU 2M32G HDC 32B SLU 2M32G
Order No. 1788490000 1788470000
109.5
a
5
a
b
a M32 M32
94 112 126
67 92.5
Ø5.5 29
21.6
Coupling housing Version Cover b (mm) w. threading without cover 83
Designation HDC 32B KLU 1M32G
Order No. 1788500000
107
74.6
b
a M32
a 94
82.5
B.93
RockStar® inserts
MixMate series – the high-capacity connectors
B
MixMate series – the high-capacity connectors
MixMate integrates axial screw contacts and TOP connection technology in one plug-in connector. The compact design allows simultaneous transmission of high currents, high voltages and signals.
Technical data S4 Standards / approvals Standards Approvals Inserts No. of poles – Power contact – Signal contact Rated voltage – Power contact – Signal contact Rated voltage to UL/CSA Rated current – Power contact – Signal contact Rated impulse withstand voltage – Power contact – Signal contact Pollution severity
S 4/0
S 6/12
S 6/6
DIN EN 61984 DIN EN 60664-1 UL/CSA
DIN EN 61984 DIN EN 60664-1 UL/CSA
DIN EN 61984 DIN EN 60664-1 UL/CSA
DIN EN 61984 DIN EN 60664-1 UL/CSA
4 (+PE)
4 (+PE)
6 (+PE) 12
6 (+PE) 6
1000 V
830 V
600 V
600 V
690 V 400 V 600 V
690 V 400 V 600 V
65 A
80 A
48 A 16 A
100 A 16 A
8 KV
8 KV
8 KV 6 KV 3
3
3
8 KV 6 KV 3
≥ 1010 Ω Glass-fibre reinforced PC (in UL list and approved for railway applications) –40 °C ... +120 °C V–0
≥ 1010 Ω Glass-fibre reinforced PC (in UL list and approved for railway applications) –40 °C ... +120 °C V–0
≥ 1010 Ω Glass-fibre reinforced PC (in UL list and approved for railway applications) –40 °C ... +120 °C V–0
≥ 1010 Ω Glass-fibre reinforced PC (in UL list and approved for railway applications) –40 °C ... +120 °C V–0
≥ 500 ≥ 500
≥ 500 ≥ 500
≥ 500 ≥ 500
≥ 500 ≥ 500
Contact resistance with min. and max. conductors
≤ 4 mΩ
≤ 4 mΩ
≤ 4 mΩ
≤ 4 mΩ
Contacts / Material Sockets and plug-in contact
Copper alloy
Copper alloy
Copper alloy
Copper alloy
Passivated silver or gold-plated
Passivated silver or gold-plated
Passivated silver or gold-plated
Passivated silver or gold-plated
2.5 - 10 mm2 (AWG 10 … 8)
1.5 - 16 mm2 (AWG 16 … 4)
2.5 - 10 mm2 (AWG 14 … 8) 0.5 - 2.5 mm2 (AWG 24 … 14)
16 - 35 mm2 (AWG 8 … 2) 0.5 - 2.5 mm2 (AWG 24 … 14)
8 mm
13 mm
8 mm
13 mm
12 mm
12 mm
1.1 - 1.7 Nm 0.45 ... 0.9 Nm
6 … 8 Nm 0.45 ... 0.9 Nm
Insulation resistance Material Temperature range Flammability to UL 94 Mechanical service life – Plugging cycles Ag - Surface – Plugging cycles Au - Surface
Surface Flexible conductor connection – Power contact – Signal contact Stripping length – Power contact – Signal contact Clamping torque/Axial connection – Screw connection
2 … 3 Nm
– Power contact – Signal contact Tools
1.1 - 1.7 Nm
Hexagon socket, 2 mm Screwdriver PE connection via plug/socket – Clamping range
SW 2 0.6 x 3.5
SW 3
SW 2 0.6 x 3.5 mm
SW 4 SD 0.6 x 3.5 or PZ 0 16 … 35 mm2
1.5/2.5 … 4/10 mm2
1.5 … 16 mm2 with cable lug
2.5 … 8 mm2
– AWG conductor
AWG 16/14 … 12/8
AWG 16 … 4
AWG 14 … 8
AWG 6 … 2
– Stripping length – Clamping torque – Blade dimensions
8 mm 0.5 – 0.8 Nm SD 0.8 x 4 mm
8 mm (for wire up to 6 mm2 only) 2 … 2.5 Nm SD 0.8 x 4 mm or PZ 2
8 mm 2 … 2.5 Nm SD 0.8 x 4 mm or PZ 2
8 mm 1.2 – 1.5 mm SD 0.8 x 4 mm or PZ 1
Note: Power contact = axial connection, Signal contact = screw connection. When used properly and as designated, the listed connectors may not be connected or disconnected if there is a live voltage or load! MixMate S6/6 with PE via axial connection with data identical to the power contact.
B.94
RockStar® inserts
MixMate series – the high-capacity connectors
B
Overview Size
Rated voltage
Rated current
No. of poles
3
1000 V
65 A
6
830 V
6
8
Tension clamp connection
Screw conn. with wire guard spring
Crimp Push In connection
Axial screw connection
Page
4+h
•
B.98
80 A
4+0+h
•
B.100
690 V
48 A
6 + 12 + h
•
•
B.102
690 V
100 A
6+6+h
•
•
B.104
B.95
Ordering data
Assembly instructions:
Type IS 2 KG IS 3 KG IS 4 KG
Qty 2 2 2
Order No. 1806630000 1806650000 1806660000
1. Strip wire, refer to the technical data for stripping length. Be careful not to twist the litz conductor! 2. Insert the litz conductor into the contact cavity until the insulation lies flush against the contact. 3. Insert the hex wrench into the corresponding contact on the mating face side. Hold the litz conductor in position when tightening the clamping nut.
Technical data Power contacts Stripping length
S4 8 mm
S 4/0 13 mm
S 6/12 8 mm
S 6/6 13 mm
Tightening torque Hex-socket wrench
1.1 – 1.7 Nm IS 2 KG
IS 3 KG
1.1 – 1.7 Nm IS 2 KG
6 ... 8 Nm IS 4 KG
Technical data Derating curves
Size 3 MixMate – 4 power contacts
Size 6 MixMate – 4 power contacts
Load current [A]
current for conductor according to EN 60947-7-1/1991 table V
Load current [A]
HDC-S4-SAS/BAS H07V-K10
current for conductor according to EN 60947-7-1/1991 table V
HDC-S4/0-SAS/BAS H07V-K1,5 Ambient temperature [°C]
Ambient temperature [°C]
current for conductor according to EN 60947-7-1/1991 table V
current for conductor according to EN 60947-7-1/1991 table V
HDC-S4-SAS/BAS H07V-K2,5
B.96
Ambient temperature [°C]
Load current [A]
B
Hex-socket wrench
Load current [A]
RockStar® Einsätze
MixMate series – the high-capacity connectors
HDC-S4/0-SAS/BAS H07V-K16
Ambient temperature [°C]
RockStar® inserts
MixMate series – the high capacity connectors
Technical data Derating curves
Size 6 MixMate – 6 power contacts/12 signal contacts
Size 8 MixMate – 6 power contacts/6 signal contacts
current for conductor according to EN 60947-7-1/1991 table V
Load current [A]
Load current [A]
current for conductor according to EN 60947-7-1/1991 table V
signal contacts unloaded
HDC-S6/12-SAS/BAS power contacts H07V-K10
Ambient temperature [°C]
B
HDC-S6/6-SAS/BAS power contacts H07V-K35
Ambient temperature [°C]
Load current [A]
current for conductor according to EN 60947-7-1
signal contacts loaded with 16 A constant
Load current [A]
HDC-S6/12-SAS/BAS power contacts H07V-K10
Ambient temperature [°C]
current for conductor according to EN 60947-7-1/1991 table V
signal contacts unloaded
HDC-S6/12-SAS/BAS power contacts H07V-K2,5
Ambient temperature [°C]
B.97
RockStarÂŽ inserts
MixMate series - the high-capacity connectors
1000 V, 65 A, Size 3 4+h Inserts Axial screw connection Insert Male
Designation HDC S4 SAS
Order No. 1789990000
Female
HDC S4 BAS
1789980000
Dimensions 34.4
51
19.5 – 21.0
41.3 23.7
Male
B Please note: only use for housings of size 16D
Female 41.3
Note
23.7
3446
27 34.4
44 51
Arrangement of contacts Male
3454
Female
Mounting cut-out 44
3462
34.4
17
27
M3
39 51
3470
B.98
RockStar速 inserts
MixMate series - the high-capacity connectors
Selection of Housings RockStar速 IP65 / IP66 Size 3 For additional housings, refer to Chapter D.
Hood Plug housing, cable entry sideways Version Cover b (mm) w. threading without cover 72
Designation HDC 16D TSLU 1M25G
Order No. 1787480000
M32 PG 21 PG 29
w. threading without cover 72 w. threading without cover 72 w. threading without cover 72
HDC 16D TSLU 1M32G HDC 16D TSLU 1PG21G HDC 16D TSLU 1PG29G
1787470000 1652560000 1652580000
a b
a M25
60
43
B
75
Plug housing, cable entry at top Version Cover b (mm) w. threading without cover 72
Designation HDC 16D TOLU 1M25G
Order No. 1787500000
M32 PG 21
w. threading without cover 72 w. threading without cover 72
HDC 16D TOLU 1M32G HDC 16D TOLU 1PG21G
1787490000 1652680000
PG 29
w. threading without cover 72
HDC 16D TOLU 1PG29G
1652700000
a
b
a M25
60 75
43
Cover Version For hoods
Designation HDC 06B DMDL 1LB
Order No. 1665210000
72
60
18
44.35
Base Bulkhead housing Cover b (mm) without cover 29 with cover 47
Designation HDC 06B ALU HDC 06B ADLU
Order No. 1202100000 1202500000
74
44.45
b 6.5
Version
60 70 82
32 43 47
Base housing Version
Designation
Order No.
M25
w. threading without cover 74
Cover
b (mm)
HDC 16D SLU 2M25G
1787520000
M25 M32 M32 PG21
w. threading w. threading w. threading w. threading
HDC 16D SDLU 2M25G HDC 16D SLU 1M32G HDC 16D SLU 2M32G HDC 16D SLU 2PG21G
1787540000 1900900000 1787510000 1652840000
92 74 74 74
5
with cover without cover without cover without cover
74.57 60
b
a
20.77
82
54.5
17.2
Cover Order No. 1665200000
75.5
60 17
Designation HDC 06B DODL 2BO
43
7
Version For bases
B.99
830 V, 80 A, Size 6 4+0 + h Inserts Axial screw connection Designation HDC S4 0 SAS
Order No. 1789960000
Female
HDC S4 0 BAS
1789970000
Dimensions 34
84.5
48
Male
B
55
31,8
55.8
31.6
3504
19.5 – 21.0
Insert Male
17.3
RockStarÂŽ inserts
MixMate series - the high-capacity connectors
43.85 13.806
Female
77.5 82
27 34
Arrangement of contacts Male
3512
Female
3520
Mounting cut-out 77.5
34
17
27
M3
71 3528
B.100
84.5
RockStar® inserts
MixMate series - the high-capacity connectors
Selection of Housings RockStar® IP65 / IP66 Size 6 For additional housings, refer to Chapter D.
Hood Plug housing, cable entry sideways Version Cover b (mm) w. threading without cover 61
Designation HDC 16B TSBU 1M25G
Order No. 1788180000
M25 M32
w. threading without cover 76 w. threading without cover 76
HDC 40D TSBU 1M25G HDC 40D TSBU 1M32G
1787010000 1787000000
45.5 a b
a M25
93.3
59
a
45.5
B
Plug housing, cable entry at top Version Cover b (mm) w. threading without cover 61
Designation HDC 16B TOBU 1M25G
Order No. 1788210000
M25 M32
w. threading without cover 76 w. threading without cover 76
HDC 40D TOBU 1M25G HDC 40D TOBU 1M32G
1787070000 1787060000 b
a M25
59
93.3
Cover Designation HDC 16B DMDQ 2QB
Order No. 1665270000 18 34
Version For hoods
93.3 136.2
55
43
Base Bulkhead housing Designation HDC 16B ABU
Order No. 1208600000
136.2
b
Cover b (mm) without cover 29
55
5.25
Version
Ø4.5
93.3 103 115
32 43 47
Base housing Version
Designation
Order No.
M25
w. threading without cover 64
Cover
b (mm)
HDC 16B SBU 2M25G
1788240000
M25 M32
w. threading without cover 84 w. threading without cover 84
HDC 40D SBU 2M25G HDC 40D SBU 2M32G
1787120000 1787110000
55
136
5
a
a
b
a
Ø5.5
93.3 105 117
45 56.5
Coupling housing Version Cover b (mm) w. threading without cover 79 w. threading without cover 79
Designation HDC 40D KBU 1M25G HDC 40D KBU 1M32G
Order No. 1787200000 1787190000
136.2
55
b
a M25 M32
a 45.5 93.3
Cover Designation HDC 16B DODQ 4BO
Order No. 1665260000
93.3
7 17
Version For bases
43 58.5
B.101
690 V, 48 A, Size 6 6+12 + h Inserts Axial screw connection Designation HDC S6 12 SAS
Order No. 1790000000
Dimensions
Female
HDC S6 12 BAS
1790010000
Male
84
33.6
47.25
Insert Male
32.25
RockStarÂŽ inserts
MixMate series - the high-capacity connectors
Please note: the signal contacts are designed for a rated voltage of 400V and a rated current of 16A.
Female 47.15
Note
77.5 84.7
15.6
3562
19.5 – 21.0
B
27 33.8
Arrangement of contacts Male
3570
Female
3578
Mounting cut-out
17
27
34
77.5
M3
71 3586
B.102
84.7
RockStar® inserts
MixMate series - the high-capacity connectors
Selection of Housings RockStar® IP65 / IP66 Size 6 For additional housings, refer to Chapter D.
Hood Plug housing, cable entry sideways Version Cover b (mm) w. threading without cover 61
Designation HDC 16B TSBU 1M25G
Order No. 1788180000
M25 M32
w. threading without cover 76 w. threading without cover 76
HDC 40D TSBU 1M25G HDC 40D TSBU 1M32G
1787010000 1787000000
45.5 a b
a M25
93.3
59
a
45.5
B
Plug housing, cable entry at top Version Cover b (mm) w. threading without cover 61
Designation HDC 16B TOBU 1M25G
Order No. 1788210000
M25 M32
w. threading without cover 76 w. threading without cover 76
HDC 40D TOBU 1M25G HDC 40D TOBU 1M32G
1787070000 1787060000 b
a M25
59
93.3
Cover Designation HDC 16B DMDQ 2QB
Order No. 1665270000 18 34
Version For hoods
93.3 136.2
55
43
Base Bulkhead housing Designation HDC 16B ABU
Order No. 1208600000
136.2
b
Cover b (mm) without cover 29
55
5.25
Version
Ø4.5
93.3 103 115
32 43 47
Base housing Version
Designation
Order No.
M25
w. threading without cover 64
Cover
b (mm)
HDC 16B SBU 2M25G
1788240000
M25 M32
w. threading without cover 84 w. threading without cover 84
HDC 40D SBU 2M25G HDC 40D SBU 2M32G
1787120000 1787110000
55
136
5
a
a
b
a
Ø5.5
93.3 105 117
45 56.5
Coupling housing Version Cover b (mm) w. threading without cover 79 w. threading without cover 79
Designation HDC 40D KBU 1M25G HDC 40D KBU 1M32G
Order No. 1787200000 1787190000
136.2
55
b
a M25 M32
a 45.5 93.3
Cover Designation HDC 16B DODQ 4BO
Order No. 1665260000
93.3
7 17
Version For bases
43 58.5
B.103
690 V, 100 A, Size 8 6+6 + h Inserts Axial screw connection Insert Male
Designation HDC S6 6 SAS
Order No. 1790030000
Dimensions
Female
HDC S6 6 BAS
1790020000
Male 111
52.1
Note
Please note: the signal contacts are designed for a rated voltage of 400V and a rated current of 16A.
Female 47.8
3620
19.5 – 21.0
B
34.4
34
104 111
13.4
RockStarÂŽ inserts
MixMate series - the high-capacity connectors
27 34
Arrangement of contacts Male
3628
Female
3636
Mounting cut-out
17
27
36
104
M3
98 3644
B.104
111
RockStar® inserts
MixMate series - the high-capacity connectors
Selection of Housings RockStar® IP65 / IP66 Size 8 For additional housings, refer to Chapter D.
Hood Plug housing, cable entry sideways Version Cover b (mm) w. threading without cover 61
Designation HDC 24B TSBU 1M25G
Order No. 1787760000
M32 M25 M32
w. threading without cover 61 w. threading without cover 76 w. threading without cover 76
HDC 24B TSBU 1M32G HDC 64D TSBU 1M25G HDC 64D TSBU 1M32G
1787750000 1786780000 1786770000
45.5 a b
a M25
59
120
Plug housing, cable entry at top Version Cover b (mm) w. threading without cover 61
Designation HDC 24B TOBU 1M25G
Order No. 1787820000
M32 M32
w. threading without cover 61 w. threading without cover 76
HDC 24B TOBU 1M32G HDC 64D TOBU 1M32G
1787810000 1786830000
45.5
a
b
a M25
59
120
Cover Designation HDC 24B DMDQ 2QB
Order No. 1665640000
22.5 38.5
Version For hoods
120 152.7
55
43
Base Bulkhead housing Version
Cover b (mm) without cover 29.3
Designation HDC 24B ABU
Order No. 1212400000 163
5.25
b
55
Ø4.5
120 130 143
32 43 47
Base housing Version
Designation
Order No.
M25
w. threading without cover 64
Cover
b (mm)
HDC 24B SBU 2M25G
1787870000
M25 M32
w. threading without cover 84 w. threading without cover 84
HDC 64D SBU 2M25G HDC 64D SBU 2M32G
1786890000 1786880000
162.7 55
5
a
a
b
a
Ø5.5
120 132 144
45 57.5
Coupling housing Version Cover b (mm) w. threading without cover 65 w. threading without cover 79
Designation HDC 24B KBU 1M25G HDC 64D KBU 1M32G
Order No. 1787920000 1786960000
55.5 45.5
163 120
b
a M25 M32
a
Cover Designation HDC 24B DODQ 4BO
Order No. 1665630000
120
7 17
Version For bases
43
B.105
B