Our 206 Series Variocrimp Crimping Tool ensures a proper, reproducible, gas-tight square or “WM” format crimp from 0.25 mm² to 50 mm²
That depends on the terminal block size and type, so there’s no single answer across the board. One syringe contains 20 ml. Please ensure that the clamping point is completely filled with Alu-Plus Contact Paste.
The type of crimp is not crucial. What is important is ensuring the correct strip length and conductor diameter, as well as a gas-tight crimp. The crimped conductor must also fit into the clamping point and be wired properly. When using ferrules, observe the manufacturer’s instructions.
The term “gas-tight” does not have a uniform definition. Therefore, gas-tight connections are assessed on the basis of a voltage drop test per IEC 60947-7-1 before and after a corrosion test, using a screwless rail-mount through terminal block. As long as the voltage drop is less than the limiting value set by the standard (3.2 mV per through connection), gas-tightness of the crimp connection can be assumed.
When working with ferrules, you should ensure a gas-tight crimp, even if this is not explicitly required or standardly stipulated.
Only CAGE CLAMP® and PUSH WIRE® spring pressure connection technology up to 4 mm² are approved for connecting aluminum conductors in connection with Alu-Plus Contact Paste. The 221 Series is not suitable for connecting aluminum and copper wires since its spring pressure connection technology differs.
Since the aluminum conductors to be connected are usually solid connecting wires, we recommend the 2273, 773 and 222 Series in connection with Alu-Plus Contact Paste as an alternative. Please ensure that all available connection points of the corresponding splicing connector are filled with the paste. Then use a cloth to remove the paste that has been displaced by the wires.
The information shown on the side walls of the 221 Series Splicing Connector housing does indeed differ. This is because different approvals apply to different locations of use: IEC and UL/CSA for Europe and PSE/JET for Japan.
Please consider the country in which you will use the 221 Series and the rating data that needs to be taken into account.
Because of the discontinuation of our 775 to 777 Series Classic Multilevel Installation Terminal Blocks, our customers are now reverting to using the 2003 and 2005 Series TOPJOB® S Multilevel Installation Terminal Blocks. In existing distribution boxes equipped with 10 x 3 mm N-busbars, expansion with the TOPJOB® S Multilevel Installation Terminal Blocks is possible using N-disconnect slide links. The position of the N-busbar for the Classic busbar carrier (777-305) is identical to the TOPJOB® S busbar carrier (2009-305).
However, when expanding an existing distribution box, note that the Classic and TOPJOB® S accessories are incompatible. Connecting the two rail-mount terminal block series – for example, commoming the phase – is not possible.
In certain cases, jumpers from different systems in our portfolio of rail-mount terminal blocks can be used to common MCS connectors.
In such cases, our Support team will be glad to provide further assistance.
Screwless connection points use clamping springs as compensating elements. Tin-plating conductors is an ideal pre-treatment for conductors in terms of voltage drop constancy and uniformity of the contact surfaces. However, this only applies to stationary installations. Full tin-plating of conductors is generally not permissible for use in equipment with vibrations, such as engines. Tin-plating is only permissible for the tip of a stranded wire as a measure to protect the splice. This has no negative effect on the contact quality or voltage drop.
For use of tin-plated conductor ends in screwless clamp connections, please note the applicable standards: DIN EN 60999-1:2000, Section 7.1, as well asDIN EN 60335-1:2001, Section 23.9. The relevant passages place limits on connectors with screw-type clamping units, but not on connectors with screwless clamping units. DIN EN 60335-1, Section 23.9, explicitly mentions spring clamps as a solution in Note 1.
As a general rule, yes – but please note that the inherent stability of a single-pole PCB terminal block is less than that of a multi-pole terminal strip. Therefore, be sure to protect single-pole terminal blocks against excessive mechanical stress, such as torsional or bending stress, both when connecting the conductor and during subsequent use. For example, use additional supports, ensure short bracing of the connected conductor, and note the corresponding handling instructions for actuation.
For soldered connections, Section 4.2.2.5 of DIN EN 60079-7:2007 requires an additional mechanical method to secure the connection.
Our 285-607/999-950 Ground Conductor Terminal Block meets this requirement through additional caulking of the soldered grounding foot. In the 285-197/999-950 Ground Conductor Terminal Block, the housing ensures the mechanical stability of the connection.
With TOPJOB® S Rail-Mount Terminal Blocks, two staggered jumpers per slot are possible. However, two pins in one jumper contact is not possible.
You can find more information on the multi-functional TOPJOB® S jumper range here.
Due to their clearance and creepage distances with a pollution degree of 3, the TOPJOB® S Rail-Mount Terminal Blocks are primarily designed for a rated voltage of 800 V. The clearances and creepage distances pertain to the potential-to-potential distances and the potential-to-rail distances.
To meet the requirements for 1,000 V, it is necessary to form a common potential. This is accomplished by commoning the rail-mount terminal blocks with the corresponding push-in type jumper bar. This eliminates the potential-to-potential clearance and creepage distances. The remaining potential-to-rail clearance and creepage distances suffice for a 1,000 V application. If multiple potentials (+, −) are located on one DIN-rail, they are separated from each other by at least 6 mm with an end stop.
We recommend end and intermediate plates whenever rail-mount terminal blocks are not completely insulated by housing of the terminal blocks. You should also insert an intermediate plate when switching rail-mount terminal block types if the open rail-mount terminal block side is not completely covered by the following rail-mount terminal block type.
End and intermediate plates not only serve as visual separation – in particular, they also prevent wiring errors and provide reliable touch-proof protection.
Rail-mount terminal blocks for Ex i applications have corresponding clearance and creepage distances and thus can be used in corresponding environments. However, customers/end users themselves are responsible for ensuring correct use of the rail-mount terminal blocks in their applications. There are no certifications or tests per Ex i for our rail-mount terminal blocks. Customers/end users bear the sole responsibility for ensuring proper use of the terminal blocks in the environments approved for them.
You can find additional information on use of electrical equipment in hazardous areas in the technical appendix (section 14) of our Full Line Catalog, volume 1. The following explanation can also be found there: “No special approval is required for terminal blocks used as simple electrical equipment for ‘Ex i’ protection type, as they do not contain a voltage source and precise information is available concerning electrical data and temperature rise performance.”
Rail-mount terminal blocks have no fixation device of their own to prevent possible slippage, so end stops are required. Either one or two end stops per terminal strip are required, depending on the arrangement of the rail-mount terminal blocks. For example, one end stop suffices if a circuit breaker or other equipment is placed on one side of the terminal strip.
End stops have a small metallic claw that protects the rail-mount terminal blocks against slippage during transport or under other operating conditions. If the end stops are provided with group marker carriers or a marker, they also serve as labeling.
Unlike the TOPJOB® S Through Terminal Block, a reduction to smaller cross-sections is not possible with the 2016 Series Supply Terminal Blocks for Distribution Boxes such as the 2016-7601. The jumper slots of the supply terminal blocks for distribution boxes are not located on the same plane as with the TOPJOB® S Through Terminal Blocks, nor can the jumper slots be arranged in a plane by rotating the individual rail-mount terminal blocks.
For a reduction to smaller cross-sections, please use the corresponding 2016 Series Through Terminal Block and the 2016-499 Step-Down Jumper.
Comb-style jumper bars and alternate comb-style jumper bars can be used in the conductor connection openings of the 279, 280, 281, 780 and 781 Series Classic Rail-Mount Terminal Blocks. A standard series operating tool (such as the 280-440) is required for insertion. Conductor connection is no longer possible where a comb-style jumper bar or alternate comb-style jumper bar has been placed.
Comb-style jumper bars and alternate comb-style jumper bars cannot be inserted into the jumper slots of the 279, 280, 281, 780 and 781 Series Classic Rail-Mount Terminal Blocks.
It is necessary to maintain clearance and creepage distances when using rail-mount terminal blocks under the following conditions:
Our 2002, 2003, 2005, 2006 and 2016 Series Installation Rail-Mount Terminal Blocks do not have UL approval.
For all applications requiring UL approval, we recommend the TOPJOB® S and Classic Rail-Mount Terminal Blocks. To implement N-disconnection or N-potential distribution with disconnect slide links, please use the 780 to 785 Series.
Step-down jumpers common terminal blocks of different sizes, without losing a conductor clamping point. Various options are available for this purpose for the 279 to 285 Series Classic Rail-Mount Terminal Blocks. These are listed below, with required jumper indicated:
Step-down jumpers common terminal blocks of different sizes, without losing a conductor clamping point. Various options are available for this purpose for the 2000 to 2016 Series TOPJOB® S Rail-Mount Terminal Blocks and for the 285 Series High-Current Rail-Mount Terminal Blocks.These are listed below, with the required jumper indicated:
According to DIN EN 60445, the housings of ground conductor rail-mounted terminal blocks that have an electrical connection to the DIN-rail (partially insulated) must be green/yellow. Each color must cover between 30 % and 70 % of the area. The specific proportions of the two colors does not matter.
Use of the green/yellow color combination is not allowed for through terminal blocks with no connection to the DIN-rail.
Different color variants of our rail-mount terminal blocks are available according to their cross-sections. Colored through terminal blocks can be used for all insulated protective ground connections, with the exception of the colors blue and green/yellow. According to IEC 60947-7-2, the green/yellow color combination is only intended for partially insulated ground conductor rail-mounted terminal blocks with a connection to the DIN-rail.
According to IEC 60947-7-1, the short-time withstand current simulates a thermal shock. However, there is no information on the pulse dynamics, i.e., how to test this. Therefore, the short-time withstand current indicated must not be considered the dynamic short circuit withstand capacity. For a dynamic short circuit situation, the applicable international standards describe neither requirements profiles nor test procedures.
The short-time withstand current value is determined from a current load of 120 A per wire cross-section, which is applied for one second, once to the clamping unit of the through terminal blocks, and three times to the clamping unit of the ground conductor terminal block. Typical short-time withstand currents for rail-mount terminal blocks according to IEC 60947-7-1 and 60947-7-2 are:
1.5 mm² – 180 A
2.5 mm² – 300 A
4 mm² – 480 A
6 mm² – 720 A
10 mm² – 1,200 A
16 mm² – 1,920 A
25 mm² – 3,000 A
35 mm² – 4,200 A
50 mm² – 6,000 A
70 mm² – 8,400 A
95 mm² – 11,400 A
120 mm² – 14,400 A
150 mm² – 18,000 A
185 mm² – 22,200 A
240 mm² – 28,800 A
300 mm² – 36,000 A
No: Our 210 Series Operating Tools are only intended for installation work on de-energized rail-mount terminal blocks.
Therefore, they do not have an approval per DIN EN 60900, which defines the grip properties, blade insulation and VDE and GS test. For this reason, neither the VDE/GS test mark nor electrotechnical rating data is affixed to our operating tools.
Our 2007 Series 2-Conductor Disconnect/Test Terminal Blocks (-8801, -8811 and -8821) are available in the following color combinations:
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