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Customer application 25 January 2022

Spring Pressure Connection Technology in Switchgear Production – Fast, Safe and Compact

Control cabinets are essential components for smooth operation in both mechanical engineering and building systems. These two industries share a key requirement: As many components as possible must be accommodated in the smallest space. For switchgear manufacturers, this is often the deciding factor in selecting the compact TOPJOB® S Rail-Mount Terminal Blocks from WAGO.

Switchgear manufacturing in Germany is dominated by mid-sized companies. Saveen GmbH, located in Weisendorf in the Franconia region of Bavaria, currently has 23 employees. This young company has grown quickly in the past few years, as CEO Sebastian Wellein reports: “Five years ago, we started with six employees – now we’re planning a new building, because our current location is bursting at the seams.” A large number of the tenders come from the home- and building automation sector. The company also produces switchgear units for specialist mechanical engineering, including automotive suppliers. Around 400 control cabinets in total are manufactured by saveen each year.

At a Glance

Compact approach with double- and triple-deck terminal blocks
Spring pressure connection technology saves wiring time and eliminates production errors
Maintenance-free terminal blocks
Straightforward CAE and CAD data download

Saving Space in the Control Cabinet

Numerous components must be housed within control cabinets; in switchgear design, as in many other applications, space is at a premium. Especially in home and building automation, many outlets are necessary, and they have to be wired from the switchgear unit. It is not unusual to have more than 100 outlets per switchgear unit. Various components are connected, from the lights, to the drives for the blinds, to the fire damper. Saveen relies on rail-mount terminal blocks from WAGO’s TOPJOB® S Series for wiring components. “If the customer doesn’t specify another manufacturer and it’s up to us, we always use WAGO components,” emphasizes Wellein. The rail-mount terminal blocks are available for conductor cross-sections from 0.14 mm² to 25 mm². Very large cross-sections are used for the power supply, while signal conductor sizes are usually small. If only larger conductor sizes are needed, WAGO’s 285 Series High-Current Rail-Mount Terminal Blocks can be used. These allow connections of conductors up to 185 mm².

TOPJOB® S Rail-Mount Terminal Blocks are particularly compact so that many connections can be accommodated on one DIN-rail. For example, a through terminal block with a nominal cross-section of 1.5 mm² is only 4.2 mm wide. Each rail-mount terminal block can be connected to conductors one size over its rated cross-section and can be loaded with the nominal current of the larger conductor – in this case, conductors with a cross-section of 2.5 mm². In home and building automation, more and more building systems are being controlled directly from the switchgear unit. “However, no one budgets for a corresponding increase in control cabinet space,” says Wellein. “So we need to make the best use of the space available.” In such cases, saveen uses double- and triple-deck terminal blocks from WAGO, which allow two to three times as many connection points in the same amount of space.

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Fast and Safe Wiring

One of the main advantages of the rail-mount terminal blocks is the spring connection technology. According to Wellein: “We have completely banished screw connection technology from our control cabinets.” The simple spring pressure connection technology of the TOPJOB® S Rail-Mount Terminal Blocks offers important advantages during assembly. Wiring requires only a few manual steps. Depending on the conductor type, conductors can often simply be inserted into the unit with the so-called push-in connection technology. At saveen, all conductors up to 16 mm² are equipped with ferrules, so they can be connected with push-in connection technology. “The spring pressure connection technology works perfectly in daily use,” says Wellein. “It not only saves time during wiring, but also helps to prevent errors during assembly.” And the terminal blocks from WAGO offer an additional advantage: They are maintenance-free. “For this reason, many customers demand this connection technology,” adds Wellein.

Efficiency in Engineering and Production

However, high-quality components are not the only factor that affects switchgear quality. The processes, from electrical design to wiring, need to be perfectly attuned to each other. “With our proprietary procedures and state-of-the-art equipment, both in the design office and in production, we can compete with larger switchgear manufacturing companies,” states Wellein confidently. Saveen generally designs its own switchgear units for home and building automation in-house. For this purpose, the four electrical engineers use the EPLAN Electric P8 CAE tool. Following the actual electrical design phase, a 3D structural design is also implemented in Pro Panel. As Wellein explains: “For efficient engineering, it’s particularly important to have corresponding CAE and CAD data for all the components used.” WAGO provides this data for all rail-mount terminal blocks from the TOPJOB® S series. It can be easily downloaded from an online platform. “It works perfectly. With one mouse click, I can load the 3D data and then easily situate the rail-mount terminal blocks on the DIN-rail during the structural planning,” says Wellein, describing the process.

The data from the electrical design is used at various points in production. Initially, the 3D data for the switchgear unit is exported from the 3D structural design in order to control an automatic CNC milling machine. “This is a fully automated process for all flat components, like control cabinet doors or mounting plates,” explains Wellein. The machine creates the through-holes, threads and cut-outs in the parts. In contrast to manual machining, this process is significantly faster and also ensures uniformly high quality. After the DIN-rails are screwed onto the mounting plates, they are populated with TOPJOB® S Rail-Mount Terminal Blocks and other components.

Straightforward Support

It can be difficult to clearly label all the connection points in an installation, especially when there are many rail-mount terminal blocks; this can lead to mismating errors. The electrical design phase directly provides the necessary data for marking: A connected WAGO Smart Printer can be directly controlled from the CAE tool to print continuous marking strips for the rail-mount terminal blocks. “The terminal block marking and the connection to the EPLAN system function quite well,” emphasizes Wellein, who appreciates the high level of efficiency in this step.

Switchgear manufacturer saveen uses the rail-mount terminal blocks in almost every project and always keeps them in stock. On average, they stockpile enough terminal blocks for one to two months at normal production capacity. According to the operations manager, WAGO’s excellent service and delivery reliability are another advantage: “Whenever we urgently need materials, WAGO can usually find a straightforward solution.”