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Seite W.1

General data

Certificates
W.2 - W.3
Electrical data
Rating the clearance and creepage distances
Current load curve

W.4 - W.6
W.7

General technical data

General information about CE marking
EMV directives
Protection types
Converting AWG conductors to mm2
Gauge pin

W.8
W.8 - W.9
W.10
W.11
W.11

Materials
Insulation materials
Metals
Current loading curves

W.12 - W.13
W.14
W.15

Technical dictionary
General data

Technical dictionary

Connection types
W.16 - W.17
ATEX
W.18 - W.19

Specific data

Terminals
Regulations / definitions
Assembling terminal strips
Connecting terminals
Use of aluminium conductors
Definition of the various types
Ex terminals ATEX

W.20
W.21
W.22
W.23
W.24 - W.25
W.26 - W.29

Relay couplers
W.30 - W.31
Opto-couplers
W.32 - W.34
Overvoltage protection
W.35 - W.41
Tools
Cutting
Stripping
Crimping

W.42
W.43
W.44

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28.10.2003

Technical Dictionary
General

SSB_W001-W044_GB.qxd

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US

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28.10.2003

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Technical Dictionary
General Data

Weidmller quality and

environmental management
for the benefit of our
customers

Product certificates create trust

Certification documents verify the quality
of our products. They are issued following
suitable tests by independent institutes
and are the prerequisite for use in certain
markets or fields of application.
The accredited test laboratory has its
expertise endorsed
The reliability of technical data is of great
importance for the user. In confirming the
accredited status, officially approved
authorities have certified the organisation
in accordance with EN 45 001 as well as
its expertise in defined assessment of
terminals, plug-in connectors, relays and
electronic equipment.
Certification as documentation of
managed quality
Quality management in the Weidmller
companies is based on ISO 9000 ff.
The corresponding certificates from
acknowledged, accredited authorities also
simplify your supplier appraisal procedures.
Verification of Weidmllers quality
also includes contracts with
independent institutions covering the
regular monitoring of production
facilities, quality management and the
laboratory.
Excellent environmental management
testifies to our total commitment. W.3

Allgemeines

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Technical dictionary
General data

Electrical data
Rating the clearance and creepage distances of electrical equipment
General information

Since April 1997, clearance and creepage

distances have been rated according to
the regulations of DIN VDE 0110-1,
Insulation coordination for equipment in
low voltage systems.
DIN VDE 0110-1 contains the modified
version of the IEC report 664-1 (see
IEC 664-1/10.92).
The latest catalogue gives the rating data
obtained for each product in compliance
with the provisions of this standard, where
applicable.

Clearance distances

Creepage distance

Clearance distances are rated in

accordance with the following factors:

Creepage distances are rated in

accordance with the following factors:

Anticipated overvoltage
Rated impuls voltage

Intended
Rated voltage

Used
Overvoltage protection precaution

Used insulation materials

Insulation materials group

Measures to prevent soiling

Degree of soiling

Measures to prevent soiling

Degree of soiling

Diagram showing clearance distance

Diagram showing creepage distance

For the rating of clearance and creepage

distances, application of the regulations
for insulation coordination produces the
following interrelationships:

Grooves are taken into account when

measuring creepage distances if their
minimum width X is rated according to
the following table:
Degree of
Minimum width
soiling
X in mm
1

0.25

1.0

1.5

2.5

If the corresponding clearance distance is

less than 3 mm, the smallest groove width
may be reduced to 1/3 of this clearance
distance.

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Technical dictionary
General data

Electrical data
Rating the clearance and creepage distances of electrical equipment
Influential factors

Rated impulse voltage

Degrees of soiling

The rated impulse voltage is derived

from:

Degree of soiling 1
No or only dry non-conductive soiling.
Soiling has no influence.

Voltage conductor earth

(the rated voltage of the network, taking
into account all networks)

Degree of soiling 2
Only non-conductive soiling. Temporary
conductivity must be expected occasionally as a result of condensation.

Overvoltage category
Table 1: Rated impulse voltage for electrical equipment
Rated voltage of the power
supply system *) in V
Three-phase One-phase
systems
systems with
mid-point

120 to 240

Degree of soiling 3

Rated impulse voltage in kV for

Electrical equipment
at the power supply
of the installation

Electrical equipment
as part of the permanent installation

Electrical equipment Specially protected

for connection to the electrical equipment
perman. installation

(Overvoltage
category IV)

(Overvoltage
category III)

(Overvoltage
category II)

(Overvoltage
category I)

4.00

2.50

1.50

0.80

230/400
277/480

6.00

4.00

2.50

1.50

400/690

8.00

6.00

4.00

2.50

1000

Values for project planning in each individual case.

If no values are available, the values in the preceding line apply.

Conductive soiling occurs, or dry

non-conductive soiling which becomes
conductive because of condensation.
Degree of soiling 4
Soiling results in constant conductivity,
e.g. caused by conductive dust, rain
or snow.

*) acc. to IEC 38

Unless explicitly stated otherwise, the

dimensioning of clearance and creepage
distances, and hence the thus-derived
rating data for electromechanical products
(terminals, terminal strips, PCB connection
terminals and plug-in connectors) is based
on degree of soiling 3 and overvoltage
category III, taking account of all network
types.

Stipulating the overvoltage

categories
according to national standard DIN
VDE 0110-1 (for electrical equipment fed
directly from the low voltage network)
Overvoltage category I

Overvoltage category III

Devices for connection to the permanent electrical installation of a building.

Outside the device, measures have
been taken either in the permanent
installation, or between the permanent
installation and the device, to limit the
transient overvoltage to the relevant
value.

Devices which are an integral part of

the permanent installation, and other
devices expected to have a higher
degree of availability.

Overvoltage category II

Overvoltage category VI

Devices for connection to the

permanent electrical installation of a
building,

Devices for use at or near the power

supply in the electrical installation of
buildings, between the principal
distribution and the mains,

e.g. domestic appliances, portable

tools.

e.g. distribution boards, circuit

breakers, distribution devices (including
cables, busbars, distribution boxes,
switches, sockets) in the permanent
installation and devices for industrial
use, and other devices such as
stationary motors with continuous
connection to the permanent
installation.

e.g. electricity meters, overcurrent

protection switches and centralised
controllers.

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Technical dictionary
General data

Electrical data
Rating the clearance and creepage distances of electrical equipment
Influence factors

Rated voltage

Insulation material group

The rated voltage is derived from the

rated voltage of the power supply and
the corresponding network type.

The insulation materials are divided into

four groups depending on the comparative
figures for creepage distance (CTI:
comparative tracking index):

Table 3a:
Single phase 3 or 2 conductor a.c. or d.c. networks
Rated voltage
of the power
supply system
(network)*)

Voltages for table 4

Voltages for table 4

for insulation confor insulation
ductor conductor 1) conductor earth 1)
all systems

Table 3b:
Three-phase 4 or 3 conductor a.c. networks

3-conductor
systems,
with mid-point
earthing

Rated voltage
of the power
supply system
(network) *)

for insulation
conductor
conductor
all systems

Insulation material group

for insulation
conductor earth
three-phase 4conductor systems with earthed neutral 2)

three-phase 3-conductor systems;

unearthed 1) or
earthed conductor

V
12.5

V
12.5

V
60

V
63

V
32

V
63

24 / 25
30

25
32

110/120/127

125

80

125

150**)

160

160

42 / 48 / 50**)
60

50
63

208

200

125

200

30-60

63

32

220/230/240

250

160

250

100**)

100

300**)

320

320

110 / 120
150**)

125
160

380/400/415

400

250

400

440

500

250

500

480/500

500

320

500

575

630

400

630

220

250

110-220
120-240

250

125

600**)

630

630

300**)

320

660/690

630

400

630

220-440

500

250

720/830

800

500

800

600**)

630

960

1000

630

1000

480-960

1000

500

1000**)

1000

1000

1000**)

1000

1) Conductor-earth insulation levels for unearthed or impedance earthed

systems are the same as those for conductor-conductor insulation
because, in practice, the operating voltage of every conductor to earth
can match the conductor-conductor voltage. This is because the actual
voltage to earth is defined by the insulation resistance and by the
capacitive blind resistance of every conductor to earth. This means that
a low (but tolerated) insulation resistance of a conductor can effectively
earth it and raise the other two to the value of the conductor-conductor
voltage against earth.
2) For electrical equipment intended both for use in three-phase 4-conductor and in three-phase 3-conductor systems, both earthed and
unearthed, only the values for the 3-conductor systems should be used.
*) It is presumed that the value of the rated voltage of the electrical
equipment is not below the value of the rated voltage of the power
supply system.
**) Following jointly undertaken alterations, the meaning of the **) marking
has not been adopted in Table 1. Its definition: the /- dash refers to a
three-phase 4-conductor system. The lower value is the voltage
external to neutral conductor, the higher value is the voltage external
to external conductor. If only one value is stated, it refers to three-phase
3-conductor systems and refers to the voltage external to external
conductor.
Tables 3a and 3b still refer to the values in Table 1 by using the **) marking.

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W.6

600 CTI

II

400 CTI < 600

III a

175 CTI < 400

III b

100 CTI < 175

The comparative tracking index is required

to have been determined using special
samples produced for this purpose with
test solution A in compliance with IEC 60112
(DIN IEC 60112/DIN VDE 0303-1).

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Electrical data

Basic curve

Technical dictionary
General data

Current load curve

(derating curve)

Current loading curve

Upper temperature limit
of the component

The derating curve shows which currents

can flow continuously and simultaneously
across all possible connections when the
component is exposed to various ambient
temperatures below its upper temperature
limit.
The upper temperature limit of a component is a rating value which depends on
the used materials. The sum of ambient
temperature and overtemperature produced by the current load (power loss at the
forward resistance) must not exceed the
upper temperature limit of the component,
so as not to damage or destroy it. The
current loading ability is therefore not a
constant value but falls with increasing
component ambient temperature. In addition, the power loading ability is influenced
by component geometry, number of pins
and connected conductor.

tg = upper temperature limit of component

tu = ambient temperature of component
ln = load current

tg =
tu =
ln =
a=
b=

The current loading ability is empirically

determined acc. to DIN IEC 60152-3.

In view of the fact that it is effectively not

possible to select components with maximum permissible forward resistances for
measurement purposes, the basic curve
has to be reduced. A reduction of the
loading currents to 80 % results in the
power loading curve. Here allowance
has to be made for the maximum tolerable
forward resistances and inaccuracies
incurred in measuring the temperatures,
so that these curves are adequate for
practical use as indicated by experience.
If, within the low ambient temperature
range, the current loading curve exceeds
the current permissible as based on the
current loading ability of the conductor
cross-sections requiring connection, then
the current loading curve is limited to the
smaller current for this temperature range.

For this purpose, the corresponding component temperatures tb1, tb2 and the ambient temperatures tu1, tu2 are measured
for three different loading currents l1, l2
The values are entered in a linear system
of coordinates (as shown in Fig. 1) to
illustrate the relationships between the
loading currents, the component ambient
temperature and the component overtemperature.
The Y-axis is used for the loading
currents and the X-axis for the ambient
temperatures. A perpendicular on the
X-axis at the component's upper temperature limit tg completes the coordinate
system

upper temperature limit of component

ambient temperature of component
load current
basic curve
reduced basic curve (current loading curve)

For every current l1, l2, .. the corresponding mean values for component overtemperatures t1 = tb1 tU1, t2 = tb2 tU2,
are entered starting from the perpendicular and working to the left.
The points found in this way are connected to form a parabolic curve.

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Technical dictionary
General data

General technical data

General information about
CE marking

EMC directives

The CE mark on various products and

their packaging is neither a quality feature
nor an indication of quality or safety.
The CE mark is a control sign that was
created and brought into effect for open
trading within the European market.
It does not refer to the address of the end
consumer. The CE mark only confirms
that a manufacturer has complied with all
of the directives of the European Union
(EU) that are applicable to this product.
Therefore the CE mark is proof of
directive conformity and is directed
towards the responsible control
authorities.
The CE mark can be said to be the
passport for products that are to be
traded within Europe.

According to the low-voltage directive, a

conformity evaluation process must be performed on the product whereby
conformity to the directive is assumed where
a reference to the harmonised European
standards or to the other technical specifications, e.g. IEC standards or national standards, is made.

Electronic Products from Weidmller

Regarding EMC Guidelines

With the decree of the Directive of the

council dated 3rd. May 1989 for the
alignment of the legal requirements of the
member states concerning electromagnetic
compatibility (89/336/EEC), the European
Union (EU) has declared EMC as a
protection objective.

passive interface elements with and

without status displays

Weidmller considers all relevant EU

directives to the best of its knowledge.
The currently applicable directives are
as follows:
73/23/EEC

The protection objectives are defined in

article 4 of the EMC directive dated 19th.
November 1992, and state the following:
the generation of electromagnetic
interference must be so reduced so that
the intended operation of radio,
telecommunications and other devices is
possible.

Electrical equipment for use within

specific voltage ranges (Low voltage
directive)

the devices must have a suitable

resistance to electromagnetic interference
in order to ensure intended operation.

89/336/EEC

Devices are defined in the EMC

directive as:

Electromagnetic compatiblity
(EMC directive)
98/392/EEC
Safety of machines (Machinery directive)

all electrical and electronic equipment,

installations and systems that contain
electrical and electronic components

The standards mentioned in the directives

have been an element of Weidmller's
standard development for a considerable
time. This provides the guarantee of
conformity to the European directives.
Our testing laboratory, accredited
according to EN 45001, performs the
standard conform testing. The testing
reports are recognised within Europe
within the framework of the accreditation
process.

This applies to active/passive components

and intelligent modules that are produced
and stored by Weidmller.

73/23 EEC
Low-Voltage Directive (LVG)

industrial installations

Electrical equipment in the sense of this

directive are all electrical equipments that
are used with a nominal voltage between
50 and 1000 Vac and between 75 and
1500 Vdc.
If an electrical product has the CE mark,
it must fulfil the requirements of the EMC
directive and if necessary the low-voltage
directive (above 50 Vac and above 75 Vdc).

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W.8

The adherence to this directive is assumed

for the devices that conform with the
harmonised European standards that, for
example, are released in the gazette from
the Federal Minister for Post and Telecommunications.
The devices are utilised in the following
areas:
medical and scientific equipment and
devices

Category 1
All passive components such as:
terminals with status displays
protection terminals with status displays

overvoltage protection
These products cause no interference and
they have a suitable immunity to interference. These products are not labelled with
the CE mark concerning the EMC directive
or the EMC guideline.
Category 2
These products are labelled with the CE
mark after the conformity evaluation
process has been performed which
contains the reference to the harmonised
European standards.
The following are harmonised standards:
EN 50081-1
Generic Emission Standard for
residential, commercial and light industrial
environments
EN 50082-1
Generic Immunity Standard for
residential, commercial and light industrial
environments companies
EN 50081-2
Generic Emission Standard for heavy
industrial environments
EN 50082-2
Generic Immunity Standard for heavy
industrial environments
EN 55011
Radio Interference for ISM Devices
EN 55022
Radio Interference for Information
Technology Facilities

information technology devices

EN 61000-3-2
Harmonics

Weidmller tests its electronic products

according to the relevant standards in order
to fulfil the agreed protection objectives.

EN 61000-3-3
Voltage Fluctuations
EN 6100 0-4-x
approx. 10 partial tests for interference
immunity; partly not ratified.

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EMC directives

Usage of Tests

Criterion B

General Installation Instructions

Generic standards are always used

when device-specific product standards
do not exist. The generic standards of
EN 50081-2 and EN 50082-2 are used
as the basis for Weidmller products.

The equipment shall continue to operate

as intended after the test. No degradation
of performance or loss of function is
allowed below a minimum performance
level as specified by the manufacturer,
when the equipment is used as intended.

In agreement with the performance level

and the criteria A and B, the products are
allowed and can be affected externally
during the occurrence of a fault.

Remark:
The relevance of EN 50082-1 for certain
products must be checked as well as how
far EN 50081-1 or 50082-1 was considered during testing.
The environment phenomenon and test
interference levels are specified in the
generic immunity standard. Additionally,
Weidmller considers the evaluation
criteria A, B and C.
Text extract from the Generic Standard
EN 50082-2:
Criterion A
The equipment shall continue to operate
as intended. No degradation of
performance or loss of function is allowed
below a minimum performance level as
specified by the manufacturer, when the
equipment is used as intended.
In certain cases, the nominal performance
level can be replaced by an permissible
loss of performance.
If the minimal performance level or
permissible loss of performance is not
specified by the manufacturer, both of
these specifications can be extracted from
the description of the product, the relevant
documentation and from what the operator expects from the equipment during its
intended operation.

In certain cases, the minimal performance

level can be replaced by an permissible
loss of performance. During testing
degradation of the performance level is
permitted however changes to the
specified operation mode or data loss are
not permitted.

Technical dictionary
General data

General technical data

It should be attempted, as far as possible,

to prevent this with an optimal installation.
Measures:
installation of the products in an
enclosed metal box (control cabinet,
metal housing)

protect the voltage supply with an

If the minimal performance level or
overvoltage protection device.
permissible loss of performance is not
(For mains supply of 230/400 Vac with
specified by the manufacturer, both of
a PU type and for 24 Vdc with an EGU
these specifications can be extracted from
or LPU.)
the description of the product, the relevant
documentation and from what the opera- only use shielded cables for analogue
tor expects from the equipment during its
data signals
intended operation.
follow ESD measures during installation,
maintenance and operation
Criterion C
A temporary loss of function is permitted,
provided the loss of function is self
recoverable or can be restored by the
operation of the controls.
Criterion B is most frequently specified in
the generic standards and is used by
Weidmller.
An example of an analogue coupler EMA:
During testing, the analogue coupler can
convert values that are outside the
permissible tolerances.
After testing however, the values must be
within the available tolerances.

distance between electronic modules

and interference sources (e.g. invertors)
and power lines should be at least
200 mm.
maintenance of ambient temperature
and relative humidity
long cables are to be protected by overvoltage protection devices.
For safety reasons, the operation of
walkie-talkies and mobile telephones
should only be performed outside a
radius of 2 m.

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Technical dictionary
General data

General technical data

Protection rating according to EN 60 529 / DIN 0470

The protection ratings are indicated by a code consisting of

the two invariable letters IP and two digits representing
the degree of protection.

Example:

I P 6 5
2nd digit: protection from water
1st digit: protection from solid bodies

Degrees of protection from water

(2 nd digit)

Degrees of protection from solid foreign

bodies (1st digit)
Number

Number

Not protected

Not protected

Protected from solid foreign bodies 50 mm in diameter and above. Protection to prevent dangerous
parts being touched with the back of the hand.

Vertically falling drops must not have any

harmful effect.

Protected from solid foreign bodies 12.5 mm in diameter and above. Protection to prevent dangerous
parts being touched with the fingers (finger-safe).

Vertically falling drops must not have any

harmful effect if the housing is inclined at an
angle of up to 15 to the vertical on both sides.

Protected from solid bodies 2.5 mm in diameter

and above. Protection to prevent dangerous parts
being touched with a tool.

Water sprayed at an angle of up to 60 to the

vertical on both sides must not have a harmful
effect.

Protected from solid bodies 1 mm in diameter and

larger. Protection to prevent dangerous parts being
touched with a piece of wire.

Water splashing against the housing from any

direction must not have a harmful effect.

Dust protected. Penetration of dust is not completely prevented, but dust must not penetrate in
quantities that would impair satisfactory working
of the device or safety.

Water sprayed against the housing from any

direction must not have a harmful effect.

Dust-proof, no penetration by dust.

Water aimed in a strong jet against the housing

from any direction must not have a harmful effect.

Water must not penetrate in any quantity which

causes harmful effects if the housing is temporarily
submerged in water under standard pressure and
time conditions.

Water must not penetrate in any quantity which

causes harmful effects if the housing is permanently
submerged in water under conditions which must
be agreed between manufacturer and user.
However, the conditions must be more adverse
than under number 7.

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Converting AWG conductors to mm2

Gauge pin acc. to IEC 60947-1 section 8.2.4.5.2 table 7

AWG is the abbreviation for American

Wire Gauge. This gives no indication of
the actual conductor cross-sectional area.

Possibility of inserting unprepared

round conductors with the largest
stipulated cross-sectional area

The relationship between AWG and mm2

is shown in the following table.

Testing with stipulated gauge, inserted

under own weight.

AWG

mm

28
26
24
22
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0

0.08
0.13
0.21
0.22
0.52
0.65
0.82
1.04
1.31
1.65
2.08
2.63
3.31
4.17
5.26
6.63
8.37
10.55
13.30
16.77
21.15
26.67
33.63
42.41
53.48

Conductor crosssectional area

Rigid conductor
(single- or multicore) mm2
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150

Technical dictionary
General data

General technical data

Pin
Form A

Form B

Designation

Diameter
a
mm

Width
b
mm

Designation

Diameter
a
mm

A1
A2
A3
A4
A5
A6
A7
A8
A9
A 10
A 11
A 12
A 13

2.4
2.8
2.8
3.6
4.3
5.4
7.1
8.3
10.2
12.3
14.2
16.2
18.2

1.5
2.0
2.4
3.1
4.0
5.1
6.3
7.8
9.2
11.0
13.1
15.1
17.0

B1
B2
B3
B4
B5
B6
B7
B8
B9
B 10
B 11
B 12
B 13

1.9
2.4
2.7
3.5
4.4
5.3
6.9
8.2
10.0
12.0
14.0
16.0
18.0

Tolerable
deviations for a
and b mm
0 0.05

0 0.06

0 0.07

0 0.08

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Technical dictionary
General data

Materials
Insulation materials
In order to satisfy all the different requirements
made of our products, we have to use various
insulation materials tailor-made to each specific
application.
All insulation materials used by Weidmller are free
from harmful substances. It is especially important
that these materials contain no cadmium. In
addition, they are free from heavy metal colour
pigments, dioxin and furan-forming substances.
Thermosetting plastics

Plastic
Abbreviation

Germin
KrG

Stamin
KrS

Epoxy resin
EP

Thermosetting plastics have outstanding dimensional stability, low water absorption, excellent
creepage current resistance and outstanding fire resistance.
Their continuous service temperature is higher than that of thermoplastics. Under high thermal
load, thermosetting plastics have better dimensional strength than thermoplastics.
Thermosetting plastics are, however, inferior to thermoplastics in terms of their flexibility.

Melamine resin
pressing compound
MF type 150
(DIN EN ISO 14 528)
Organic filler

Melamine resin pressing

compound
MF type 156
(DIN EN ISO 14 528)
Inorganic filler

Epoxy resin
with
inorganic filler

mid-yellow

anthracite

black

high continuous service

temperature

continuous service
temperature higher
(than Germin)

very good electrical

properties

Colour

Description

high fire resistance

high creepage current
resistance
inherent flammability
protection

high fire resistance

very high continuous service

temperature

high creepage current

resistance

resistant to high-energy
radiation

inherent flammability
protection

halogen- and phosphorousfree; flame retardant

108

1014

Properties
Specific forward resistance acc. to IEC 93
Dielectric strength acc. to IEC 243-1
Creepage current resistance (A) to IEC112

1011
10

12.5

160

600

600

600

Upper max. tol. limit temperature

130

140

160

Lower max. tol. limit temperature, static

60

60

60

V-0 (5 V-A)

V-0 (5 V-A)

V-0

Combustibility acc. to UL 94
Fire behaviour acc. to railways standard

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Technical dictionary
General data

Materials

Thermoplastics

Wemid
Wemid is a modified
thermoplastic whose
properties are especially
tailored to make it suitable for
use in our power connectors.
Advantages over PA include
enhanced fire protection and
higher continuous service
temperature. Wemid fulfils the
strict requirements for use in
railway vehicles according to
NF F 16-101.

Polyamide
PA
Polyamide (PA) is one of
the most frequently used
technical plastics. The
advantages of this material
includes its very good
electrical and mechanical
properties, flexibility and
resistance to breakage.
In addition, its chemical
structure gives PA good fire
resistance even without the
use of flame retardants.

Polyamide
PG GF
Glass-fibre reinforced
polyamide (PG GF)
offers excellent dimensional
stability and very good
mechanical properties.
This makes it ideal for use as
end bracket.
Unlike PA, this material in
unreinforced state comes
under combustibility class HB
in accordance with UL 94.

Polybutylene
terephthalate PBT

Polycarbonate
PC

Thermoplastic polyester
(PBT)
offers excellent dimensional
stability (which is why it is
used for plug-in connectors)
and high continuous service
temperature. It has lower
creepage current resistance
than other insulation
materials.

special Weidmller
insulating material

insulating material

insulating material

with or without
glass-fibre reinforcement,
depending on use

with or without
glass-fibre reinforcement,
depending on use

dark beige

beige

dark beige

orange

grey

higher continuous
service temperature

flexible, resistant
to breakage

excellent dimensional
stability

high dimensional
stability

high dimensional
stability

enhanced fire resistance

good electrical and

mechanical properties

very good mechanical

properties

good electrical and

mechanical properties

high continuous service

temperature

flame retardant, without

dioxin and furan-forming
substances

high electrical insulating

power

1013

1016

halogen- and phosphorousfree; flame retardant

self-extinguishing properties

low smoke
permitted for use in railways
acc. to NF F 16-101

1012

1012

1012

halogen-free;
flame retardant

25

30

30

28

30

600

600

500

200

175

120

100

120

115 / 130

115 / 125

50

50

50

50

50

V-0

V-2

HB

V-0

V-2 / V-0

I2 / F2 *)

I2 / F2

W
*) also qualified acc. to
LUL E 1042

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Technical dictionary
General data

Materials
Metals

Weidmller uses only tried and tested

materials for the electrical components in
its products.
All materials are subjected to rigorous
quality monitoring under a quality
management system certified to
DIN EN ISO 9001.
Environmental compatibility plays a crucial
role in the selection of materials.
All metals used by Weidmller are
selected, processed and surface-treated
according to the very latest technical
findings.

Steels

Conductive materials

Steel parts whose function is to

permanently maintain contact force are
zinc electroplated, with an additional
chromate layer added to provide
additional passivation.

The current-carrying materials copper,

brass and bronze are characterised by
both high conductivity and good
mechanical properties.

Surface protection complies with the very

highest standards. Results from laboratory
tests are incorporated in producing the
surface finish.
Zinc still offers corrosion protection over a
longer period of time even if the zinc
coating is partially damaged by scratches
or pores.
Zinc acquires a negative charge in relation
to steel under the influence of an
electrolytic fluid. The metal ions in the zinc
migrate to the steel giving the base
material lasting protection against
corrosive attack.

W
W.14

The surfaces are usually finished with tin

plating. This guarantees that the contact
has outstanding adaptive properties with
low transition resistance. The tin plating
not only gives consistently good electrical
properties but also affords excellent
protection from corrosion.
Soldered connections are also provided
with tin plating. To safeguard soldering
ability over longer periods of time (storage
periods), brass parts are also given an
additional nickel layer to serve as a
diffusion barrier.
The nickel layer is highly effective in
preventing zinc atoms from diffusing
out of the brass.

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Materials

The maximum current which a terminal

can carry depends on:

Technical dictionary
General data

Current loading curves

Current loading curve

for upper continuous service temperature 100C polyamide 66
35

the inherent temperature rise of the

terminal

30

the ambient temperature

An upper service temperature has been

defined for every Weidmller terminal, and
this must not be exceeded in continuous
operation.

25
Loading current [A]

the cross-sectional area of the

connected conductor

10

0
0

10

20

30

40

60

70

80

90

100

110

120

130

140

100

110

120

130

140

100

110

120

130

140

Current loading curve

for upper continuous service temperature 120C Wemid
35
30
25
20
15
10
5

Thermoplastic (polyamide 66)

WEMID

10

20

30

40

50

60

70

80

90

Ambient temperature T [C]

Duroplastic (MF 150 KrG)

Current loading curve

for upper continuous service temperature 130C MF 150 KrG

Depending on the insulation material

used, the rating current can be conducted
up to an ambient temperature of 55 C for
PA 66, 75 C for Weidmllers insulation
material WEMID, or up to 85 C for
duroplastic insulation materials (KrG).

35
30
25
Loading current [A]

Above these temperature limits, the

current is to be reduced in accordance
with the current expectancy curves.

50

Ambient temperature T [C]

Loading current [A]

Figs. 13 show examples of current

heating curves (in this case for a rated
current of 32 A) for three different
insulating materials:

15

The continuous service temperature

depends on the insulation material used in
the terminal. According to EN 60 947-7-1,
a terminal may not heat up by more than
45 K.
When the input current is at least
equivalent to the rated current, the
maximum ambient temperature to which
a terminal may be subjected is equal to
the continuous service temperature for
the insulation material used, less the
maximum tolerable temperature rise of
the terminal acc. to EN 60 947-7-1.

20

20
15
10
5
0
0

10

20

30

40

50

60

70

80

90

Ambient temperature T [C]

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Technical dictionary
General data

Connection types
Clamping yoke connection

Pressure clamp connection

Weidmllers tension clamp system

optically combines the specific properties
of steel and copper. The system has
proven its worth billions of times over in
various Weidmller products. Both the
tension clamp and the clamping screw
consist of hardened steel. This clamping
yoke unit generates the necessary contact
force. Connection of the conductor
involves the tension clamp pressing the
conductor against the busbar, which is
made of copper or
high-quality brass. Weidmllers tension
clamp produces a gas-tight, vibrationresistant connection between the conductor and the busbar.

With its patented pressure clamp connection, Weidmller has developed a

screw connection system for conductors
with large cross-sectional areas. The
screw unit can be taken right out of the
terminal, making it easier to insert larger
conductors (which often otherwise proves
difficult). The conductor is placed directly
on the busbar, the screw unit replaced
and the conductor clamped in position.

Weidmllers TOP connection system

fulfils the requirement that conductor
insertion and screw actuation take place
in parallel. This brings wiring advantages
in certain installation situations, for
example with close lateral spacing in
installation boxes. The TOP connection
system combines the special properties of
steel and copper. The hardened steel
pressure clamp presses the conductor
directly against the copper or brass
busbar. The high contact force guarantees
a gas-tight connection between
conductor and busbar.

Vibration resistance
The force generated by turning the
clamping screw means that the upper
thread overlap springs back and exerts
a counter-effect on the screw.

Vibration resistance
The difference in length d between the
shank of the clamping screw and the
resilient pressure clamp means that the
pressure clamp undergoes elastic
deformation when the screw is tightened.
The high spring force of the pressure
clamp gives rise to vibration resistance
and at the same time counteracts the
tendency for the connected conductor to
settle. It is not, therefore, necessary to
tighten the clamping screw.

Vibration resistance
The force exerted by the steel pressure
clamp when the screw is tightened pulls
the two halves of the TOP connection
thread apart, as in the tension clamp.
This exerts a braking effect on the screw
and guarantees outstanding vibration
resistance.

Weidmllers tension clamp system is

vibration-resistant.

Any settling of the connected conductor

is counteracted by the elastic behaviour of
Weidmllers tension clamp. This means it
is not necessary to tighten the clamping
screw.

W.16

TOP connection

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Connection types
IDC technology

Direct push in technology

Weidmllers tension clamp system

functions in similar fashion to the tried and
tested clamping yoke. As with the latter,
the tension clamp preserves the
separation of mechanical and electrical
functions. The tension clamp of highquality rust- and acid-resistant steel pulls
the conductor against the galvanised
copper busbar. The surface-treated
busbar has low contact resistance and is
highly resistant to corrosion. These
properties are preserved by the balancing
effect of the tension clamp.

IDC (insulation displacement

connection) technology is a means of
connecting copper conductors which
involves absolutely no preparation of the
conductor in other words, no stripping
and no crimping.

Direct push in technology involves the

stripped solid conductor simply being
pushed into the terminal as far as it will go
thats all there is to it. No tools are
required, and a reliable, vibration-resistant
and gas-tight connection is produced.
Even flexible conductors with crimped wire
end ferrules or ultrasonic welded
conductors can be connected without any
problems.

When the conductor is connected, its

insulation is penetrated and, at the same
time, the electrical contact is produced
between the conductor and the busbar.
As with the other types of connection,
Weidmllers IDC principle ensures
separation of mechanical and electrical
functions.
A stainless steel spring presses the busbar
against the conductor, thus guaranteeing
low contact resistance and a gas-tight,
vibration-resistant connection.

Technical dictionary
General data

Tension clamp connection

A stainless steel spring, held in a separate

cage, guarantees that the conductor
exerts a strong contact force on the
busbar (copper- and tin coated). The
conductor pull-out forces are even higher
here than in the tension spring system.
In the steel cage, a spring and a
conductor stopper guarantee optimum
conditions for connection and guide the
screwdriver for the purpose of releasing
the conductor.

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Technical dictionary
General data

ATEX
ATEX 95 (formerly ATEX 100a)

Protection class
The former directive for Ex protection
Protection
Code
issued by the European Council under
76/117 EEC became invalid with effect
Gen. requirements

from 1 July 2003. Now only directive

Oil encapsulation
o
94/9/EEC or ATEX 95 applies (ATEX:
Overpressure encapsulation
p
Atmosphre Explosive); this is one of the
Sand encapsulation
q
so-called new approach directives.
Pressure-resistant encapsulation
d
It applies in all countries of the European
Increased safety
e
Union together with Iceland, Liechtenstein
Inherent safety
ia
and Norway.
Inherent safety
ib
In these countries it refers to the sale and
Type n (EEx n)
n
commissioning of products which have
Sealing encapsulation
m
been specially developed for areas in
which the presence of gases, vapours, fog
or dust give rise to a potentially explosive
atmosphere. It now also covers the mining Classification for explosion-risk areas
industry and purely mechanical devices.
CENELEC
Presence of a potentially
The ATEX directive has been in force since
March 1996. It was valid on an optional
basis through to 30 June 2003 (interim
period) in parallel to the existing directives.
As of this date, all new systems and devices for installation in explosion-risk areas
must conform with the ATEX directive and
be certified accordingly. The former categorisation into zones (zone 0, 1 or 2) and
protection classes (e.g. i: inherent safety,
e enhanced safety) still apply.

classification
IEC60079-10

explosive atmosphere

Zone 0
Zone 20
Zone 1
Zone 20
Zone 2
Zone 22

constant, long-term
or frequent
occasional
rare and
short-term

CENELEC
EN

IEC

50014
50015
50016
50017
50018
50019
50020
50020
50021
50028

60079-0
60079-6
60079-2
60079-5
60079-1
60079-7
60079-11
60079-11
60079-15
60079-18

Device category
explosion-protected

2
2
2
2
2
1
2
3
2

Device
category

US ClassifiFlammable
cation NEC 500 media

1G
1D
2G
2D
3G
3D

Class I, Div 1
Class II, Div 1
Class I, Div 1
Class II, Div 1
Class I, Div 2
Class II, Div 2

Gases, vapours
Dust
Gases, vapours
Dust
Gases, vapours
Dust

Explosion groups
Gas (e.g.)

CENELEX

NEC 500

Propane
Ethylene
Hydrogen
Acetylene
Methane (mining)

IIA
IIB
IIC
IIC
I

D
C
B
A
Mining (MSHA)

Max. surface
temperature (C)

Temperature class
CENELEC

Temperature class
NEC 500-3

450
300
280
260
230
215
200
180
165
160
135
120
100
85

T1
T2

T3

T4

T5
T6

T1
T2
T2A
T2B
T2C
T2D
T3
T3A
T3B
T3C
T4
T4A
T5
T6

Temperature classes

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ATEX
Technical dictionary
General data

ATEX 95 (formerly ATEX 100a)

Marking example
Terminal WDK 4 N V
Rated conductor cross-sectional area

Rated voltage

Device group II - above ground

(gases, vapours, fog, dust)

CENELEX protection class

e enhanced safety

Device category 2
use in zone 1 or 21
Device group II
above ground
(gases, vapours,
fog, dust)

Approved for use in gases

G and/or dust D

European symbol for

explosion protection

Approval number

Example of marking
Assembled enclosure
for enhanced safety

CENELEC ignition protection

e enhanced safety
Approved for use
in gases G

Device category 2
Use in zone 1

Device group II above ground

(gases, vapours, fog, dust)
Temperature class T6

Max. surface temperature without

dust ignition 100C

Enclosure protection > IP64

Approval number
Device category 2
use in zone 21
Approved for use
in dust D

Rated voltage

Rated conductor
cross-sectional area

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Technical dictionary
General data

Terminals
Regulations / definitions

Terminals acc. to VDE 0611-1

This standard was published in Germany
in August 1992:
VDE 0611-1 Low-voltage switchgear
part 7: Ancillary equipment section 1
Terminal blocks for copper conductors.
The contents of this standard correspond
to the international standard:
IEC 60947-7-1:
1989 Low voltage switchgear and control
gear part 7: Ancillary equipment section 1
Terminal blocks for copper conductors
At the European level this standard has
been ratified by CENELEC, making it valid
in the following countries:
Austria, Belgium, Denmark, Finland,
France, Germany, Greece, Holland, Iceland, Ireland, Italy, Luxembourg, Norway,
Portugal, Spain, Sweden, Switzerland,
United Kingdom
Combined application in order of priority:
IEC 60947-1
Low-voltage switchgear and control gear
part 1: General Rules
EN 60947-1
VDE 0660 part 100
Low-voltage switchgear part 1:
General Rule
Scope VDE 0611-1
(EN 60947-7-1)
(IEC 60947-7-1)
This standard stipulates the requirements
for terminals with screwed or screwless
terminal strips intended primarily for industrial or similar use, with the terminals
fastened to a carrier to produce both electrical and mechanical connections
between copper conductors. It applies
to terminals used for connecting round
copper conductors with a cross-section
between 0.2 mm2 and 300 mm2 (AWG
24/600 kcmil), and for electronic circuits
up to 1000 Vac 1000 Hz or up to 1500
Vdc.
Remarks:
This standard is also used as guide for
special kinds of terminals (e.g. isolating
terminals) for which no special standards
are available.

W
W.20

CE mark

Terminals/
feed-through terminals

Rated surge voltage

DIN VDE 0110-1 / VDE 0660 part 100

An insulating part which carries one or

several mutually insulated terminal arrays
intended for fastening to a carrier.

Peak values of a surge voltage which can

be applied to the terminals and to which
the clearance distances acc. to VDE 0660
part 100 or DIN VDE 0110-1 refer.

Rated cross-section
The rated cross-section of a terminal is
the cross-section of the conductor to be
connected by the terminal as stated by
the manufacturer. It is determined by certain thermal, mechanical and electrical
requirements, and is one of the specifications marked on the terminal.
The rated cross-section is selected from
the following standard cross-sections:
0.2 0.5 0.75 1 1.5 2.5 4 6
10 16 25 35 50 70 95 120
150 240 300 mm2.
The terminals have a rated connection
capability, which is at least two stages
smaller than the rated cross-section. The
conductors may be solid, stranded or
flexible and, if necessary, may have their
ends pre-treated. The rated cross-section
is verified using the gauges stipulated by
VDE 0660 part 100 table 7 (see page
W.14).
Rated current
Each rated cross-section is assigned a
particular test current stipulated by
VDE 0611-1. At these rated currents, terminals are not subject to non-permissible
increases in temperature.
mm2
A

1.5
17.5

2.5
24

4.0
32

6.0
41

mm2
A

10
57

16
76

25
101

35
125

mm2
A

50
150

70
192

95
232

120
269

mm2
A

150
309

185
353

240
415

300
520

Rated voltage
VDE 0611-1 / VDE 0660 part 100
The rated voltage of a terminal is the rated
insulation voltage to which the insulation
tests and creepage distances refer. It is
defined analogously to DIN VDE 0110-1,
and is one of the specifications marked
on the terminal.

Degree of soiling
DIN VDE 0110-1 / VDE 0660 part 100
The degree of soiling stipulates the influence of solid, liquid or gaseous foreign
particles, which may reduce the dielectric
strength or specific surface resistance
(see also page W.5).
Terminals for use in the industrial field of
application are assigned degree of soiling
3: either conductive contamination may
occur or, alternatively, dry, non-conductive
contamination which becomes conductive
in the likely event of condensation.
The minimum clearance distance is stipulated in combination with the rated surge
voltage in VDE 0660 part 100 or DIN
VDE 0110-1.
Operating conditions
Terminals can be operated under the
following normal conditions:
Ambient temperature 5 C +40 C,
mean temperature 24 h + 35 C
Altitude up to 2000 m a.s.l.
Relative humidity 50% at + 40 C, 90%
at 20 C.

CE mark
A EU directive stipulates that labelling with
the CE mark is carried out by the manufacturer. The mark indicates to the state
authorities that the item complies with the
relevant directives. It thus guarantees free
trade within Europe.
Conductor connectors from 50 V ~ /
75 V- comply with the basic safety requirements stated in the low-voltage directive
73/23/EEC (amended by 93/68/EEC).
CE marking acc. to the marking directive
93/68/EEC has been mandatory since
1 January 1997.
It is affixed to the packaging.
Declarations of conformity are kept available for inspection by the relevant national
supervisory agencies as part of the technical documentation.

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Terminals

Mounting and end brackets

Dimensions

Terminal strips mounted from left to right

The overall dimensions of the terminals

with fastening parts are stipulated, but
without tolerances. A mounting tolerance
of 0.2 mm must be added to the terminal
width when planning projects.

Closed side on the left, open side on

the right
Open side of the terminal always closed
using end plates or partition plates
(WAP/TW; ZAP/TW and IAP)
End brackets placed at the beginning
and end of the terminal strip
End bracket not required next to PE
terminals. Exceptions: WDK/PE and
ZPE

Partition plate
The partition plate is necessary for visual
separation of circuits or for electrical
separation of neighbouring crossconnections.

Partition disc
Terminals

Combinations of different terminals

End plates or partition plates (WAP/TW,
ZAP/TW and IAP) must be used when
the contour changes.
For adjacent terminals with differing
rated voltages, end plates or partition
plates (WAP/TW, ZAP/TW and IAP)
must be used in order that the
respective rated voltages are adhered
to.
When the PE terminal is positioned next
to or between corresponding feedthrough terminals of the same series
and size, this does not influence the
rated voltage or rated surge voltage of
the feed-through terminals.

Partition discs can be retrofitted between

cross connectors or sockets in terminals
up to a max. terminal width of 12 mm.

Compliance with the rated insulation

voltage
The required stripping length for every
Weidmller product is stated in mm.
These lengths, such as < 6 mm 0.5
mm, > 10 mm 1 mm, must be adhered
to. This also applies when using ferrules.
The external dimensions of crimped
ferrules must comply with IE 60947-1
(1999 version).

Technical dictionary
General data

Assembling terminal strips

Working on electrical connection

elements with non-insulated
screwdrivers
Work using non-insulated screwdrivers
may only be carried out in disconnected
systems.
The following five safety rules must be
observed when disconnecting a system
before beginning work and in order to
ensure the system remains disconnected
at the working site for the duration of this
work:
Disconnect
Secure to prevent the system from
being switched on again
Ascertain that the system is not live
Earth and short circuit the system
Cover or cordon off any
neighbouring live parts
These five rules constitute the safety
precautions for working with electrical
systems and equipment. The measures
to be taken in accordance with operating
and local conditions, e.g. for high- and
low-voltage overhead lines, cables or
switchgear, are stipulated in detail in
VDE 0105 part 100.
Live terminals which are not in use
Any terminals which are not in use and
which could carry live voltage are to be
fitted with suitable covers (e.g. ADP 1...4)
to prevent them from being inadvertently
touched. The clamping screws of terminals, which are not in use, even those
that are not live, are to be screwed tight.
VDE 0105 part 100
Operation of electrical installations:
Work
Troubleshooting with two-pole voltage
detectors including voltage tester acc. to
IEC 61243-3.

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Technical dictionary
General data

Terminals
Connecting terminals

Two conductors in one terminal

The optimum solution in terms of allocating conductors to individual circuits and
marking and organising individual functional units involves just one conductor
being connected to each terminal.
If it is necessary to connect two conductors with the same cross-section in one
terminal, then this may be carried out using
W-series terminals (screw connection).
DIN IEC 60999-1 does not prohibit the
use of twin ferrules for connecting two
conductors in one terminal point using
Z-series terminals (tension spring
technology).
DIN IEC 60999-1 prohibits the use of
screwless IDC terminals (I-series) for
connecting two conductors.
Continuous current for two
conductors
The total current of two conductors must
not exceed the continuous current of the
terminal. The continuous current is the
maximum current, which a terminal can
carry without the increase in temperature
exceeding 45 K.

Conductor connection with pressure

clamp for large cross-sections
It is now no longer necessary to force
conductors with large cross-sections into
the terminal: they can be inserted simply
and easily into the terminal block. All
terminal types are available not only as
individual terminals but also in block
versions with three-, four- and five-pole
blocks. All blocks are firmly screwed
together to offer additional distortion
resistance. Longitudinal holes in the
bottom of the terminals allow for direct
assembly.
Terminal blocks can be screwed directly
to mounting plates with a 25 mm grid.
Other advantages include:
constant transfer of forces with selfadjusting connection system
any mounting direction possible
finger-safe (VBG 4) even with crossconnection
extremely distortion-proof

Tightening the clamping screws in this

torque range guarantees:
secure, gas-proof clamping
no mechanical destruction of the
tension clamp
voltage drop far below the required limit
The test torque acc. to IEC 60947-1
(supplemented by Annex C1 of
IEC 60947-1-7 or the torque stated by
the manufacturer) is the lower value of the
torque range, at which all tests are
successfully passed.
The upper value of the torque range is the
maximum torque to be applied by the
user.
The electric screwdriver should preferably
be set to the middle torque of the
clamping torque range.
The table gives the generally applicable
values. Product-specific data are listed
elsewhere for the respective products.
Products with head screw with slotted head
Thread

Rated insulation voltage

The rated insulation voltage of the terminal
does not change when two conductors
have been connected correctly.

Torque ranges for clamping screws

Open cover and

remove screw unit

M 2.5
M3
M 3.5
M4
M5
M6

Torque range
Steel screws
min. 8.8
[Nm]
0.40.8
0.51.0
0.81.6
1.22.4
2.04.0
2.55.0

A 2/A 4-80
[Nm]
0.40.8
0.51.0
0.81.6

Products with head screw with slotted head

Thread

Cross-connection systems
Weidmllers WQV and ZQV crossconnectors are systems which are fully
insulated and finger-safe in the event that
they are directly (and inadvertently)
touched; they are available with different
numbers of poles (2-pole to 50-pole).
Note: the rated voltage is always reduced
when using cross-connections.

Insert conductor
and replace screw
unit

M4
M5
M6
M8
M 10
M 12
M 16

Partition plates or end plates must be

used with these cross-connections to
preserve the rated voltage.
Close cover and tighten
screw with Allen key

W.22

Cu 5 (CuNi 60)
[Nm]

0.51.0
0.81.6
1.22.4
2.04.0
2.55.0

Products with head screw with hexagon

Thread

Cross-connections which have been cut

off do not, however, offer this protection if
the cut edge is directly (inadvertently)
touched.

M 2.5
M3
M 3.5
M4
M5
M6

Torque range
NE screws
Cu 2 (CuZn)
[Nm]
0.40.45
0.50.6

1.21.9
2.03.0

Torque range
Steel screws
[Nm]
1.22.4
2.04.0
3.06.0
6.012
10.020
14.031
25.060

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Terminals

Weidmller terminals are suitable for the

direct connection of solid round and
sector-shaped aluminium conductors.
Unlike copper, aluminium has certain
material properties, which have to be
taken into consideration when it is used as
a conductor in electrical systems.
When exposed to air, the bare surface of
the aluminium immediately becomes
covered with a thin, non-conductive layer
of oxide. This increases the contact
resistance between the aluminium
conductor and the busbar in the terminal.
In the worst case, this may develop into a
so-called glowing contact.
In the case of stranded conductors, this
phenomenon is exacerbated by the
contact resistance of the individual wires.
Despite these disadvantageous
properties, aluminium conductors can be
connected to Weidmller terminals if the
reduced rating currents for aluminium
conductors and the following assembly
instructions are observed:
1. Carefully clean the oxide layer from the
stripped end of the conductor, for
example using a knife.
Caution: do not use brushes, files or
sandpaper, to which aluminium particles
may adhere and be transferred to other
conductors.
2. Immediately after removing the oxide
layer, rub neutral grease such as acidand alkali-free Vaseline into the end of
the conductor and connect it directly to
the terminal.
3. After disconnecting the conductor,
repeat 1 and 2 prior to reconnection.
4. The instructions only apply to solid
round or sector-shaped aluminium
conductors.

Technical dictionary
General data

Use of aluminium conductors

solid round or sector-shaped

Terminal type

Rated cross- section

W-series
WDU 2.5
WDU 4
WDU 6
WDU 10
WDU 16
WDU 35
WDU 70
WDU 120
SAK series
SAK 2.5
SAK 4
SAK 6
SAK 10
SAK 16
SAK 35

mm2
2.5
4
6
10
16
35
70
120

stranded
W-series
WFF 35
WFF 70
WFF 120
WFF 185
WFF 300

Reduced rated
Thread size of
current when
terminal screw
connecting an
aluminium conductor
A
20
M 2.5
27
M3
35
M 3.5
48
M4
64
M5
105
M6
163
M8
230
M 10

Tightening torque

Nm
0.5
0.6
1.2
2.0
3.0
4.0
10.0
15.0

2.5
4
6
10
16
35

20
27
35
48
64
105

M 2.5
M3
M 3.5
M4
M4
M6

0.5
0.6
1.2
2.0
2.0
4.0

35
70
120
185
300

105
163
230
300
409

M6
M8
M 10
M 12
M 16

3.0
6.0
10.0
15.5
30.0

Tips during installation:

When tightening the terminals, it is
advisable to hold up the conductor to
avoid deformation to the mounting rail and
to keep the foot of the terminal free of
torsion forces.
Stranded aluminium conductors are
connected to terminals using an
aluminium cable lug selected according to
its conductor shape and connected by
following the instructions issued by the
cable lug manufacturer.

Fastening screw

Aluminium side

Aluminium
cable lug
Aluminium

Copper-plated
aluminium washer
Copper side

conductor
Busbar

Copper-plated aluminium washers are

necessary for the transition from aluminium cable lugs to the busbar of the
terminals. This is the only way to ensure
reliable transition from copper to aluminium. The washers are fitted so that the
copper side is in contact with the busbar
and the aluminium side with the aluminium
cable lug.

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Technical dictionary
General data

Terminals
Definition of the various types
PE terminals

Fuse terminals

Multi-storey distribution terminals

Fuse terminals consist of a terminal base

and a fuse insert holder.

A multi-storey distribution terminal is a unit

with clamping points for connecting
and/or linking external, neutral and PE
conductors to their fastening support with
a conductive PE connection.

PE
A PE terminal is a component with either
one or several clamping positions for
connecting and/or branching PE conductors (PE and PEN conductors) with a
conductive connection to their support.
Partially insulated PE terminals are
insulated from adjacent live parts of
terminals; the partial insulation is marked
green/yellow.
Scope (IEC 60947-7-2)
This standard applies to PE terminals (with
PE function) up to 120 mm2 and to PE
terminals (with PEN function) for sizes
upwards of10 mm2 with screw clamping
points or screwless clamping points for
connecting round copper conductors with
a cross- section between 0.2 mm2 and
120 mm2 (AWG 24/250 kcmil) for circuits
up to 1000 Vac 1000 Hz or up to 1500
Vdc. PE terminals are used to produce the
electrical and mechanical connection
between copper conductors and the
fastening base.
PEN function
Acc. to IEC 60947-7-2, only copper
mounting rails may be used for application
of the PEN function. Steel mounting rails
must not be used.

TN-C system supply

from 16 qmm

PEN-bridge
WQB

Einsatz der TS 35 x 15
Use of TS 35 x 15

In order to comply with the current

capability required by IEC 60947-7-2, the
TS 35 x 15 mounting rail must be used for
PE terminals with a rated cross-section of
16 mm2 and upwards.

W.24

In the case of fuse terminals for lowvoltage fuse inserts (D-system), the
technical data are defined by IEC
60947-7-3 in conjunction with VDE 0636
part 301.
In the case of fuse terminals for device
protection fuse inserts, the technical data
are defined by standard IEC 60947-7-3
pertaining to the specific range of
applications of these products.
Fuse terminals for device protection are
rated for a certain maximum power loss
on the basis of standard IEC 60127-2
valid for G-fuse inserts.
The product pages contain details about
the maximum power loss for individual or
composite arrangements for short-circuit
and/or overload protection.

These terminals can be fitted on top of or

next to each other and assembled to form
terminal strips.
They have several connection levels, all of
which are isolated from each other.
Scope IEC 60947-7-1 / IEC 60947-7-2
DIN VDE 0611-4 (partially)
These standards apply to multi-storey
distributor terminals with clamping points
and screw connections, and/or screwless
connections for connecting or linking
solid, stranded or flexible copper
conductors. In distributor terminals,
external conductor and/or N and PE
conductor connections are all present
together within a confined space.
The N-conductor can be divided for
insulation measurement; it is not used
for disconnecting or switching.

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Terminals

Neutral conductor isolating terminals

Technical dictionary
General data

Definition of the various types

Measuring and isolating terminals

Isolating terminals

Measuring and isolating terminals are

used for partial disconnection of circuits
for measuring purposes in unloaded state.

Isolating terminals are used for operational

disconnection of circuits in unloaded state.

NT

A neutral conductor disconnect terminal is

a unit with clamping points for connecting
and/or linking neutral conductors with
disconnect connection.
These terminals can be fitted on top of or
next to each other and assembled to form
terminal strips.
Rated voltage
IEC 60947-7-1
IEC 60947-1
The rated voltage given conforms to IEC
60947-7-1. It is the rated insulation
voltage and is defined acc. to IEC 60947-1
or IEC 60947-7-1.
400 V applies to
external conductor / external conductor

The rated voltage of the measuring and

isolating terminal is the rated insulation
voltage, to which the insulation tests and
creepage distances refer.
It is defined acc. to IEC 60664-1 and is
one of the specifications marked on the
terminal.
The opened disconnect point is
dimensioned according to the allocated
rated surge voltage.

The rated voltage of the isolating terminals

is the rated insulation voltage to which the
insulation tests and creepage distances
refer, and is defined acc. to IEC 60664-1.
The opened disconnect point is dimensioned acc. to the rated surge voltage
allocated for devices with disconnect
function acc. to DIN VDE 0100-537 and
IEC 60947-7-1.
The disconnects of the isolating terminals
are rated for unloaded actuation (use
category AC20 acc. to IEC 60947-1) and
used to clear a system or part of a
system.

250 V applies to
external conductor / N-conductor
external conductor / PE conductor
N-conductor / PE conductor

W
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Technical dictionary
General data

Terminals
Ex terminals
Confirmed according to the new
European Ex-Directive 94/9/EC ATEX

Basic specifications
IEC 60947-7-1 (EN 60 947-7-1/ VDE 0611P.1) and IEC
60 947-7-2 (EN 60 947-7-2/ VDE 0611P.3) are the basic specifications for terminals, and also protective conductor terminals.
For use in potentially explosive atmospheres the following
standards also apply: EN 50 014 (IEC 60 079-0/
VDE 0170/0171 P.1) and for increased safety e EN 50 019
(IEC 60 079-7/
VDE 0170/0171 P. 6). Ex terminals are so-called Ex-components according to EN 50014.
Components means any item essential to the safe functioning
of equipment and protective systems, but with no autonomous
function.
Components according to the Ex-directive 94/9/EC are not
marked with CE.
Ex terminals are certified for the type of protection increased
safety e.

According to the directive 94/9/EC, the European notified

bodies have been issuing EC-type examination certificates of
the so-called ATEX-Generation since 1997 in accordance with
EN 50014 / 50019 and the Ex directive 94/9/EC.
A prerequisite is a notification of the manufacturers quality system. This exists for Weidmller since 1997. Copies of these
type examination certificates, the notification document and the
declarations of conformity are available on request in electronic
form.
The former component certifications (A to D generation) according to the Ex directive 76/117/EEC are still valid until
30/6/2003.
The clamping yoke, tension clamp and IDC clamping system of
the terminals provide increased protection against self-release,
and are so designed that conductor ends of flexible conductors
do not have to be pre-prepared. The cross-sections and
connection data specified in the selection tables are included in
the certification.

Marking
Ex-RL94/9EG: T II 2 G D
Ex electrical equipment
T
II 2 G Equipment group II category 2 (zone 1 electrical
equipment)
II 2 D
Equipment group II category 2 (zone 21 electrical
equipment)
EN
50014/19: EEx e II
E
Conformity with EN standards
Ex
Explosion protection
e
Increased safety
II
Equipment group
KEMA 97ATEX4677U (Example)
KEMA Notified body
ATEX Conformity with 94/9/EC
U
Component
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Ex terminals
Confirmed according to the new
European Ex-Directive 94/9/EC ATEX

Electrical data
The specified values of the current carrying capacity are related to an ambient
temperature of 40 C. At rated current
load (+ 10%), the temperature of the
currentbar of the terminal increases by
a maximum of 40 K.

Accessories
The accessories listed in the tables can
be used, and are listed in the Ex certifications. To maintain the creepage and
clearance distances for e, end plates or
partitions should be used, as specified in
the table.

Recognizing an additional factor of safety

according to EN 50 014, gives the following results:
Temperature class

50 C to + 40 C

T4 to T1

50 C to + 55 C

Therefore, there is no requirement for certification when being used in intrinsicallysafe circuits.
The terminals are light blue to ensure clear
identification and easy recognition.
These terminals conform to the construction type as terminals corresponding to
the EEx e specifications.

Ambient temperature

T6, T5

Design for EEx i

Terminals for i intrinsically-safe circuits
are passive components, whose temperature-rise behaviour and the electrical characteristics are known.

Technical dictionary
General data

Terminals

If the real ambient temperature is higher,

the permitted operating current must be
reduced accordingly. As defined in
EN 50 014, the continuous operating
temperature for Wemid and KrG is
100 C, for PA material 80 C.

Accessories
The accessories listed in the tables can be
used and conform to EN 50 020
(IEC 60 079-11/VDE 0170/0171 P. 7).
Mounting
The general statements also apply here for
EEx i applications. Additionally, the EEx i
requirements always apply to the complete circuit, therefore also for parts in nonpotentially explosive atmospheres.

Current carrying capacity of cables and conductors

Rated currents
Crosssection

VDE 0298 Part 4 (IEC364-5-523)

Current carrying capacity of conductors
Ambient temperature 30 C
Routing type C + 3
for PVC 70 C conductors
A

1.5
2.5
4
6
10
16
25
35
50
70
90
120
150
185
240
300

17.5
24
32
41
57
76
101
125
150
192
232
269
309
353
415
520

Ambient temperature 40 C
Factor 0.87
Routing type C + 3
for PVC 70 C conductors
A

15.225
20.88
27.84
35.67
49.59
66.12
87.87
108.75
130.5
167.04
201.84
234.03
268.83
307.11
361.05
452.4

EN 50019 2nd. edtition

Increased-safety type of protection connection terminals
Ambient temperature 40 C
40 K rise
Current equivalent to
connect conductor
A

Clampability of 2 conductors in EExe

For our W-series terminals, it is fundamentally permitted to connect 2 wires to each
clamping point. It is, however, necessary
to use the next size down from the rated
wire cross-section. For detailed information see section Terminals.

15
21
28
36
50
66
88
109
131
167
202
234
267
307
361
452

The current carrying capacity of cables and conductors in the installation is normally
specified at 30 C ambient temperature according to VDE 0298 Part 4.
At 40 C, the operating current shall be reduced by a factor of 0.87.

W
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Technical dictionary
General data

Terminals
ATEX cross-connection instructions

Arrangements of terminals and cross-connections

The maximum voltages for Eex e applications given below are
determined on the basis of the terminals used, their cross-connection
and which of the arrangements A-J is used.

A Continuous

B Adjacent

C Adjacent

Not separated by a partition plate

or end plate

E Adjacent to a PE terminal
(earth)
Without partition plate or end plate

D Skipping

Separated by a partition plate

or end plate

F Adjacent to a PE terminal
(earth)

Bridging one or several not connected

terminals (e.g. every third)

G Bridging a PE terminal (earth)

H 2 parallel cross-connections

With partition plate nor end plate

3 parallel cross-connections

Maximum voltage
Family 1)

Certificate no.

AKZ ...
AKZ 1.5

SIRA 02ATEX3001U

Rated
voltage

Maximum voltage (V)

Rated
Nominal
current cross-section

(letters refer to the above diagrams)

mm2

175

15

1.5

175

175

175

175

175

175

175

AKZ 2.5

SIRA 02ATEX3001U

175

21

2.5

175

175

175

175

175

175

175

AKZ 4

SIRA 02ATEX3001U

275

28

4.0

275

275

275

275

275

275

275

SIRA 01ATEX3247U

275

28

4.0

175

175

275

175

275

KEMA 02ATEX2241 U

275

15

1.5

275

275

275

275

IDU 1.5N

KEMA 02ATEX2241 U

275

15

1.5

275

275

275

275

275

275

275

275

IDU 2.5N

DEMKO 03ATEX134054 U

550

21

2.5

550

420

550

550

550

550

550

550

IDU 2.5N/ZF

DEMKO 03ATEX134054 U

550

21

2.5

550

420

550

275

275

550

275

550

IDU 2.5N/ZB

DEMKO 03ATEX134054 U

550

21

2.5

550

420

550

275

275

550

275

550

IDU 1.5 TE/E

KEMA 99ATEX4329 U

275

15

1.5

275

275

275

110

275

275

110

275

IDU 2.5 TE/E

KEMA 99ATEX4329 U

275

21

2.5

275

275

275

110

275

275

110

275

MK 3/.../E

SIRA 01ATEX3248U

275

21

2.5

175

175

275

175

MK 6/.../E

SIRA 01ATEX3249U

420

36

6.0

275

275

420

275

BK ...
BK 2/E ... BK 12/E
I-series / IDK ...
IDK 1.5N
I-series / IDU ...

MK ...

1)

Please refer to the catalogue and the certificate showing precisely

which article is approved.

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Maximum voltage
Family 1)

Certificate no.

Rated
voltage
V

Rated
current
A

Rated crosssection
mm2

Maximum voltage (V)

(letters refer to the above diagrams)

SAK 2.5

KEMA 97ATEX1798 U

550

21

2.5

550

550

550

175

550

550

175

SAK 4

KEMA 97ATEX1798 U

550

28

4.0

550

550

550

175

550

550

175

SAK 6N

KEMA 97ATEX1798 U

550

36

6.0

550

550

550

175

550

550

175

SAK 10

KEMA 97ATEX1798 U

550

50

10.0

550

550

550

175

550

550

175

SAK 16

KEMA 97ATEX1798 U

750

66

16.0

550

550

550

175

550

750

175

SAK 35

KEMA 97ATEX1798 U

550

109

35.0

550

550

550

175

550

550

175

SAK-series

Technical dictionary
General data

Terminals

W-series / WDK ...

WDK 1.5/R3.5

KEMA 99ATEX6545 U

275

15

1.5

175

175

275

175

175

WDK 2.5

KEMA 98ATEX1687 U

275

21

2.5

275

275

275

60

275

275

60

WDK 2.5N

KEMA 00ATEX2061U

550

21

2.5

550

550

550

275

550

550

275

WDK 4N

KEMA 00ATEX2061U

550

28

4.0

550

550

550

275

550

550

275

WDU 1.5/ZZ

KEMA 98ATEX1685 U

550

14

1.5

550

550

550

110

550

550

110

110

WDU 2.5/1.5/ZR

KEMA 98ATEX1685 U

550

15

1.5

550

550

550

110

550

550

110

110

WDU 2.5/TC

SIRA 02ATEX3153 U

50

15

1.5

W-series / WDU ...

WDU 1.5/R3.5

KEMA 99ATEX6545 U

275

2.5

175

175

275

175

175

WDU 2.5N

KEMA 98ATEX1683 U

420

21

2.5

420

420

420

110

420

420

110

WDU 2.5

KEMA 98ATEX1683 U

550

21

2.5

550

550

550

110

420

550

110

110 2)

60 3)

WDU 4

KEMA 98ATEX1683 U

750

28

4.0

750

750

750

110

420

750

110

WDU 6

KEMA 98ATEX1683 U

550

36

6.0

550

550

550

110

420

550

110

WDU 10

KEMA 98ATEX1683 U

550

50

10.0

550

550

550

110

420

550

110

WDU 16

KEMA 98ATEX1683 U

750

66

16.0

750

750

750

110

750

750

110

WDU 35

KEMA 98ATEX1683 U

750

109

35

750

750

750

110

750

750

110

WDU 70N/35

KEMA 98ATEX1683 U

750

167

70

750

750

750

750

750

WDU 70/95

KEMA 98ATEX1686 U

750

202

70

750

750

750

750

750

WDU 120/150

KEMA 98ATEX1686 U

1100

234

120

1100

1100

1100

1100

1100

WDU 240

KEMA 01ATEX2186 U

750

300

240

WDU 4 SL

SIRA 02ATEX3242 U

275

28

275

275

275

175

275

275

175

175

WDU 6 SL

SIRA 02ATEX3242 U

275

36

275

275

275

175

275

275

175

175

WDU 10 SL

SIRA 02ATEX3242 U

275

50

10

275

275

275

175

275

275

175

175

Stud terminals / WFF ...

WFF 35

KEMA 98ATEX1684 U

1100

109

35

1100

1100

1100

1100

1100

WFF 70

KEMA 98ATEX1684 U

1100

167

70

1100

1100

1100

1100

1100

WFF 120

KEMA 98ATEX1684 U

1100

234

120

1100

1100

1100

1100

1100

WFF 185

KEMA 98ATEX1684 U

1100

307

185

1100

1100

1100

1100

1100

WFF 300

KEMA 98ATEX1684 U

1100

452

300

1100

1100

1100

1100

1100

KEMA 97ATEX4677 U

275

18

2.5

275

275

275

275

275

275

275

Z-series / ZDK ...

ZDK 2.5/1.5
Z-series / ZDU ...
ZDU 1.5

KEMA 01ATEX2106 U

550

15

1.5

275

275

275

175

275

550

175

275

ZDU 1.5/3AN

KEMA 01ATEX2106 U

550

15

1.5

275

275

275

175

275

550

175

275

ZDU 1.5/4AN

KEMA 01ATEX2106 U

550

15

1.5

275

275

275

175

275

550

175

275

ZDU 2.5

KEMA 97ATEX2521 U

550

21

2.5

275

275

275

275

275

275

275

275

ZDU 2.5/2X2AN

KEMA 97ATEX2521 U

550

21

2.5

ZDU 2.5/3AN

KEMA 97ATEX2521 U

550

21

2.5

275

275

275

275

275

275

275

ZDU 2.5/4AN

KEMA 97ATEX2521 U

550

21

2.5

275

275

275

275

275

275

275

ZDU 4

KEMA 97ATEX2521 U

550

28

275

275

275

275

275

275

275

275

ZDU 6

KEMA 97ATEX2521 U

550

36

275

275

275

275

275

275

275

275

ZDU 6/3AN

KEMA 00ATEX2107 U

550

36

275

275

275

275

275

275

275

ZDU 10

KEMA 99ATEX5514 U

550

50

10

550

550

550

550

550

ZDU 10/3AN

KEMA 00ATEX2107 U

550

50

10

550

550

550

275

550

550

ZDU 16

KEMA 99ATEX5514 U

550

66

16

550

550

550

550

550

ZDU 16/3AN

KEMA 00ATEX2107 U

550

66

16

ZDU 35

KEMA 00ATEX2107 U

750

109

35

550

550

550

550

750

ZDU 2.5-2/3AN

KEMA 97ATEX4677 U

550

21

2.5

420

420

420

275

550

550

275

110

ZDU 2.5-2/4AN

KEMA 97ATEX4677 U

550

21

2.5

ZDUA 2.5-2

KEMA 97ATEX4678 U

275

20

2.5

275

275

275

110

275

275

110

ZDUB 2.5-2/...

KEMA 97ATEX2755 U

550

21

2.5

1)

Please refer to the catalogue and the certificate showing precisely

which article is approved.

2)

For ZQV, the outer channels must be used in these cases.

3) Only possible with ZQV.

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Technical dictionary
General data

Relay couplers

Owing to their universal foot design,

Weidmller relay modules can be fitted
together on the TS 32, TS 35 x 7.5 and
TS 35 x 15 mounting rails in accordance
with the European standards EN 50 035
and EN 50 022. In the coil circuit of the
relay module, an LED status display
indicates the switching state of the relay.

Arrangement of the contacts in a

protective circuit

Switching small and large power

ratings

When switching inductive or capacitive

loads, switching functions occur which
influence the electrical service life of the
relays.

For automation technology, Weidmller

supplies EGR EG7 relay couplers for
switching the smallest power ratings (up
to 40 W) under resistive load, so that the
signals can be reliably transferred to
controllers.

Wear in the contacts can be reduced by

using the following protective circuits:

The RS31 relay coupler is used for

switching large power ratings in the
energy and supply industry. It guarantees
a switching power rating of up to 3.5 kVA
under resistive load.

Diode:
+

US

Contact types
Load
Last

Several types of contact and

combinations are available ex stock.

UD

1 NCC

EGR EG2, EGR EG7,

RS 30

Advantage:

Can be used for all power ratings,

low overvoltage, minimum space
required, low cost
Disadvantage: Very considerable release delay

1 NOC

EGR EG2, EGR EG7,

DKR, RS 30

1 NCC and
1 NOC

EGR EG2, WRS

2 NOCs

WRS

3 NOCs

WRS

1 change-over
contact

EGR EG2,
EGR/RST EG7, WRS,
DKR, PRS/PRZ MCZ R, Advantage:
RS 30, RS 31
EGR EG2, WRS,
RS 32, PRS/PRZ

4/8/16 changeover contacts

RSM

Response delay typically < 10 ms

Release delay typically < 12 ms
Switching behaviour/load limit curves
(depending on type)

Diode and Z-diode:

2 change-over
contacts

Switching times of the relay modules

US

Load
Last

UZD

Low overvoltage (as determined by

Z-diode), only slight release delay
Disadvantage: Cannot be used for large power
ratings

Contact service life under resistive load

RC combination:

(~)

(~)

US
R

Load
Last

URC
C

Advantage:

Low overvoltage, only slight release

delay
Disadvantage: Higher current load on contacts
when switching on, more complicated and expensive at higher
power ratings

dc load limit curve under resistive load

Varistor:

(~)

(~)
Last
Load

US

VDR

UVDR

Advantage:
Only slight release delay, low cost
Disadvantage: Cannot be used for all operating
voltages and power ratings
US
1
2

W
W.30

voltage curve
closing
opening

Reduction factor
under inductive load cos < 1
No. of cycleseff = no. of cycles
(at cos < 1) x reduction factor F

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Relay couplers with plugged relay

Notes on application

Relay couplers with plugged relay are of

only limited suitability in an environment
subject to extreme vibrations. Preference
should be given to relay couplers with
soldered relay.

The triggering parameters must be

precisely adhered to when using UC
versions in dc circuits. Owing to their precircuitry, UC versions consume more
current at the moment they are switched
on. The internal current limit of the
standard initiators available may mean
that the triggered relay couplers are not
switched through.

Derating curve
The contact resistance of the relay
contacts is a key factor contributing to
temperature increase inside relay
modules. This relationship is illustrated by
a derating curve, produced by plotting
tolerable current against ambient
temperature.
The current (Curve a) is determined for
the following operating conditions:
Continuous operation
Rated input voltage +10%
Several relay modules working under
load without any spacing, mounted
horizontally on a mounting rail
When the modules are mounted with
spacing > 20 mm, this results in a higher
current load (Curve b). The function b
also indicates the maximum values for
switching or short-term operation in the
horizontally mounted state.

Technical dictionary
General data

Relay couplers

Relay couplers with 24 V ac/dc input are

not suitable for triggering by initiators.
Here we recommend using a purely dc
version.

RC combinations
Long leads are particularly prone to
electrical and electromechanical
influences.
This may lead to malfunctions and even
failure of the relay module. An upstream
RC combination can prevent this by
filtering out the interference.
RC combinations are available for all
common relay couplers, either plug types
(PLUGSERIES) or as terminals WDU 12C
and DKU 12C.

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Technical dictionary
General data

Opto-couplers

Owing to the increasing degree of

automation, the electrical isolation
between control circuits (control side /
field side) is becoming increasingly
significant. The connection between the
controller, which is the key component of
every automated system, and the various
sensors and actuators must be electrically
safe and free of any feedback. Optocouplers are finding increasing use here.
They provide the necessary degree of
safety and have additional beneficial
features such as:
Low power consumption on the
controller side
High switching frequency
No contact bounce
Wear-free switching
Insensitive to vibrations
Can be used position insensitivity
No mechanical parts
Long service life
High insulation voltage
These properties make opto-couplers a
good alternative to the classical,
mechanical relay interface.
Weidmller offers modules with different
input voltages and enclosure technologies
for industrial use.

Basic structure of the opto-coupler

interface:
The key component is the actual
optoelectronic component (opto-coupler),
which is responsible for the coupling.

Output
control
circuit

Input
control
circuit

Sender

Receiver

One important variable of this component

is the current transfer rate (CTR).
The CTR factor is stated as a percentage
and describes the relationship between
dispensed input current IF and the
maximum available output current IC.
Example: IF = 10 mA; CTR = 100 %
=> IC = 10 mA.
However, the CTR is influenced by certain
parameters, which cause it to decrease
over time, such as:
ambient temperature
degree of efficiency of the luminiscence
diode
geometric dimensions within the
component
In consequence, the switching thresholds
also change over time (although this is
partly the result of aging).
CTR as
a%

t ( service life)
CTR curve over operating time

W
W.32

To eliminate this effect as far as possible,

Weidmller almost exclusively uses
optoelectronic semi-conductors with high
long-term stability in terms of CTR
behaviour.
The insulation strength of the component
is also important, because this is where
the actual coupling of the input and output
circuits takes place by optical transfer.
This means that even in the event of a
fault, the optical component must
guarantee separation of both circuits.
By using opto electronic coupling
elements in accordance with DIN
VDE 0884, Weidmllers opto-couplers
offer the highest possible safety
standards.
The circuitry within the module as a whole
must also be considered, so that the
entire module complies with DIN
VDE 0106 part 101, for example in terms
of protective separation.

Basic circuit diagram of the opto electronic

component

Opto-couplers for galvanic or

protective separation
The chief prerequisite for protective
separation with optoelectronic coupler
modules is the partial discharge level test
acc. to DIN VDE 0884. Double or
reinforced insulation for protective
separation must be resistant to partial
discharge. High-voltage testing, a
standard procedure for relays, is not
possible with semi-conductors because it
may actually destroy them. In the case of
coupler modules with integrated optocouplers, protective separation for the
stated rated voltage is achieved when the
following requirements are satisfied:
Opto-couplers tested to DIN VDE 0884
Creepage and clearance distances on
circuit boards and connection elements
comply with EN 50 178, DIN VDE 0106
or 0109

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Load side of the opto-coupler

interface

Pure dc input: Here there is a polarity

reversal protection diode, which
prevents damage to the module in the
case of reversed input polarity
.

Possible demands made of the load side

of the opto-coupler modules include:
power amplification
ac/dc and dc/ac signal conditioning
short-circuit protection
interference immunity.

Weidmller opto-coupler modules have

been rated and developed for various
different applications.

To meet these requirements, the modules

are assembled with additional electronic
elements, which then define the overall
functioning of the opto-coupler module.
ac/dc input:

Here it is not possible to reverse the

polarity of the dc input signal. The
disadvantage of the ac/dc input circuit
(with dc signal trigger) is the lower
switching frequency of the module,
because the charge capacitor (CL,
necessary for ac input signals) reduces
the maximum switching frequency.
AC input:

Accordingly, there are always two versions

of the load side of the opto-coupler:
output as
2-pole or
3-pole circuit

Opto-coupler modules are usually

specified as having an output supply
voltage range such as 5 48 Vdc.
The voltage should on no account ever
be higher or lower than these values. The
load current should not be higher than the
stated maximum output current. If this
value were constantly exceeded, the
output level would be destroyed.
Derating diagrams show the relationship
of output current to ambient temperature
(indicated for the products on the following
pages).

2-pole ac output
circuit example

Zero voltage sitch

Controller side of the opto-coupler

interface
A distinction is made between three basic
circuits on the input side of the optocoupler interfaces

2-pole dc output

A special semi-conductor module (TRIAC)

is used for switching ac voltages in the
output level of the optocoupler. Here, as
with the dc output , consideration must
also be given to the key data (voltage,
frequency, maximum load current, ambient
temperature, etc.).

*switching possibility

Use of the zero voltage switch ensures

that load is only switched on at the zero
crossover of the voltage. The modules are
always equipped with suitable protection
elements (varistor, RC combination) as
protection from non-permissible voltage
peaks.

The 2-pole dc output can be compared

with a conventional switch. In this version,
it does not matter where the load is
located (in the output circuit), although the
necessary output supply voltage must be
available with the right polarity.

Technical dictionary
General data

Opto-couplers

*switching possibility

Here again, the charging capacity has a

major influence on the maximum
switching frequency of the module as a
whole.
Weidmller Opto-couplers with ac/dc or
ac input signals are rated for mains
frequencies of approx. 40 . 60 Hz. In
the case of ac input signals, the maximum
switching frequency of the opto-coupler
module is less than half the mains
frequency. A higher switching frequency is
not possible, because this would result in
constant switching in the rhythm of the
mains frequency.

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3-pole dc output

In order to function safely, this kind of

output level required potential-related
output supply voltage with a single output.
It is rated for either positive switching (joint
reference potential: GND or 0V) or
negative switching (joint reference
potential: positive voltage pole).
Standards:
The following standards are complied
with:

Protection circuits
All opto-coupler modules have a protection
circuit in the output (usually with a recovery
diode).
The load side must be protected to
prevent interference signals from coupling
into other lines.

protection

load

Technical dictionary
General data

Opto-couplers

Protective circuit for dc output

protection

load

EN 50178:
Electronic equipment for use in power
installations
DIN VDE 0106 part 101
Protection from dangerous body currents,
basic requirements for protective
separation in electrical equipment

Protective circuit for ac output (for more details see

Over-voltage protection, chapter 7).

DIN VDE 0884

Optoelectronic couplers for protective
separation

Application exampless

DIN VDE 0109

Insulation coordination for equipment
within low-voltage systems, including
clearance and creepage distances for
configured printed circuit boards

PLC

Inputs

Opto-coupler output

Opto-coupler output

Opto-coupler input

Opto-coupler input

actuator
e.g. solenoid

Monitoring
an actuator

W
W.34

PLC

Inputs

Namur
initiator

Position message
with Namur initiator

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Gas charge eliminator

Varistors

These voltage-dependent resistors consist

of zinc oxide. Varistors are available in
different types, with disk varistors the preferred form. If the varistor is connected to
the maximum tolerable voltage, then a fault
current of just a few A flows through it.

Suitable overvoltage protection measures

can almost fully eliminate such problems.

The gas charge eliminator consists of an

insulating body (a metallised aluminium
oxide tube or glass tube), with vacuumtight connections to two or three electrodes made of special alloys. The gas
charge eliminator, which is filled with inert
gas, conducts to earth the energy associated with the overvoltage and, at connection voltages < 100 V and short-circuit
currents < 0.1 A, reverts to its highresistive state once the overvoltage has
subsided. A pre-fuse is required.

Protective elements

The gas charge eliminators used by

Weidmller are not tritium-doped.

The electronic equipment of electrical

systems is becoming increasingly
complex.
Programmable logic controls and PC
applications are replacing connectionprogrammed controls (relay technology).
Faults caused by overvoltage or switching
operations in the systems may cause
failure or damage of the system parts.

Voltage-limiting protective elements:

Gas-filled gas charge eliminators
Voltage-dependent resistances
(varistors)
Voltage-dependent diodes
(suppressor diodes)

Technical dictionary
General data

Overvoltage protection

Varistors are tested by the manufacturer

to DIN IEC 68 and according to the quality
confirmation system CECC 42000
(DIN 45923).

In compliance with CCITT (Volume IV,

K.12) and DIN 57845/VDE 0845, the
nominal data for the gas charge eliminator
are given in the catalogue.

DIN IEC 68 names the mechanical/

climatic conditions according to which the
mechanical conditions are verified. These
include for example vibrations and shock,
together with the climatic conditions for
the varistors, e.g. part 2-3 humidity/
temperature for 56 days, 40 C,
93% rel. hum., operating temperature
range 40C + 90C.

DC operating voltage:

Storage temperature to + 125C.

This is determined at a du/dt of approx.
CECC 4200 covers specifications such as
100 V/s (static behaviour), with a tolerance
voltage strength (> 2.5 kW), surge current
of up to + 20 %.
derating (8/20 s), insulation resistance
> 1 GOhm and the typical response time
Impulse sparkover voltage:
< 25 ns.
This is determined at a du/dt of approx.
1000V/s (dynamic behaviour).
U
U
Typical values are < 800V.
Leakage current:
Here two procedures are used:
DIN VDE 0432 part 2, IEC 68 and CCITT.
Input pulse

DIN IEC 68 states the mechanical/climatic

conditions under which the mechanical
conditions are verified. These include
vibrations, shock, and the climatic conditions for the gas charge eliminators, e.g.
part 2-3 humidity/temperature for
21 days, 40 C, 93 % rel. hum., operating
temperature range 40 C + 90 C.

kV

0,5

0,5

1 s

When the varistor is operated at standard

mains impedances, varistor types S14 or
S20 should be used.
S14 can be protected by a fuse of max.
10A, S20 with max. 16A.
The energy absorption (2ms) of the
varistors ranges from 0.3J to approx.
200J depending on the type.

1 s
t

Input pulse

Output pulse

The capacity of the varistors depends

on the type, ranging from 0.1 to 37 nF
at 1 kHz.

The typical capacity of the gas charge

eliminator is several pF.
kV

CCITT: 10 loads (8/20 s) at 3-minute

intervals or acc. to VDE: 5 loads (8/20 s)
at 30 s intervals.
Typical values are 5, 10, 20 kA.

Output pulse

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Technical dictionary
General data

Overvoltage protection
Varistor approvals

Suppressor diodes

Combination circuits

Underwriters Laboratories, Inc. (UL)

Suppressor diodes work similarly to zener

diodes, but in this application they work
much faster than zener diodes, with
response times ranging from a few ps to
5 ns. Energy absorption (1 ms) of the
suppressor diodes ranges from 0.3 J to
1.5 J depending on the type.

Combinations of the above mentioned

individual components result in fine
overvoltage protection modules which can
be customised to meet individual
demands. If a voltage pulse reaches the
input of this unit, then the gas charge
eliminator ignites and discharges a high
current. The remaining pulse is attenuated
by a downstream inductor and then taken
up and limited by the varistor or
suppression diode. If the gas charge
eliminator does not respond, i.e. voltage
increases more slowly, then the pulse is
processed only by the varistor or diode.

UL 1414 across-the-line components:

File E77005 (N) for type series
S05/S07/S10/S14/S20, in voltage
stages K130 to K300
UL 1449 transient voltage suppressors:
File E77005 (M): all disk types preferably
integrated within DKU, EGU, PLU, RSU
Canadian Standards Association (CSA)
Class 221 01 Accessories and Parts for
Electronic Products
All disk types with a voltage > 115 V;
for use as across-the-line transient
protectors: file LR 63184

The typical capacity of the diodes at

1 MHz ranges from 9500 pF to 360 pF.
Depending on the type, the suppressor
diodes can convert max. 1500 W into
heat for power of 1 ms duration. If the
diode is overloaded, the P-N contact
closes briefly. If the energy supply
continues, the P-N contact self-destructs.

The sequence of individual components

results in an increase in response
sensitivity in the output direction. An
interference voltage with an increase of
1 kV/s and a peak of 10 kV at the input
is limited to approx. 600 700 V by a
gas-filled surge arrester.

These diodes can be used in applications

such as protective circuits for coils or in
combination with gas charge eliminators
Protection class I, protection rating IP00,
and varistors.
test regulations CECC 42200, test
report no. 90.1 02484.01 dated 17.7.91 Suppressor diodes are supplied as unidirectional and bi-directional types. In the
for type series S05/S07/S10/S14/S20
24 Vdc overvoltage protection module,
Weidmller frequently uses the unidirectional diodes. This adjusts the typical
voltage values in the blocked direction to
29 A and 0.7V in the passage direction.
Schweizerischer Elektrotechnischer
Verein SEV

600

600

600

10

500

500

500

400

400

400

6
4

300
200

300
200

300
200

100

100

kV
12

100
s 0

s 0

0
0 20 40 s 60

Voltage curve at protection circuit EGU2

UB

Input pulse

Output pulse

The second stage, which is decoupled

from the first by an inductor, then limits
this value to approx. 90 V.
The voltage pulse is reduced by the
suppression diode to approx. 35 V for
a 24 V module.
The following electronic component is
therefore only required to withstand a
voltage pulse of approx. 1.5 x UB.

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Overvoltage protection

Overvoltages on instrumentation and

control signals and on data and power
supply lines can cause considerable
interference with operations.
Under certain circumstances, failure of the
electronic systems or entire installations
may have serious consequences, even
including personal injury.
Among the causes of overvoltages are
atmospheric discharge and switching
procedures. Overvoltages are relevant in
the following areas:
Remote engineering
Signalling systems
Data processing systems
Process terminals
Control engineering

Technical dictionary
General data

Applications for fine overvoltage

protection in instrumentation and
control engineering

Application areas for fine overvoltage

protection:
In instrumentation and control stations,
field lines coming in from sensors and
actuators have to be protected from
overvoltage, as do the sensors themselves.
Power stations, water treatment plants
or sewage plants must be protected
not only from direct lightning strikes but
also from the remote effects of lightning. The large area covered by the
plant and the extensive electrical installations used to encompass this area
must be equipped with fine overvoltage
protection.

Machines controlled by frequency

converters modulate mains voltages
with high-frequency interference, thus
influencing other electronic modules.
Power supply lines and data lines from
computers and their peripheral
equipment must be protected to allow
for safe, reliable operation.

Meteorological stations
These installations must be protected
from overvoltage.

It is essential in the interests of safety

that traffic engineering systems, such
as locks and signal systems, be
equipped with overvoltage protection
modules.

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Technical dictionary
General data

Overvoltage protection
Introduction:
Overvoltage protection in terminal
format:
Mini-conditioner
Use

Installation of overvoltage protection

circuits

Combination circuits

A protection concept for the installation

The above components can be combined
must involve all leads being protected with to produce highly effective overvoltage
overvoltage protection products.
protection terminals (MCZ OVP). The gas
charge eliminators can discharge high
Overvoltage protection for power
currents.
networks (PU B / PU C)
The varistors and suppressor diodes
absorb the residual voltage, and the
integrated inductors are responsible for
de-coupling.
The energy is discharged via a TS contact. In addition, a tension clamp is
available for PE connection.
Mounting rail contact
Contact with the mounting rail is produced
automatically by snapping the components on.
The TS 35 must be earthed for energy
prevents damage to low-voltage consumer discharge of up to 10 kA (8/20s) via the
MCZ terminals. For EMC-related reasons,
installations and electronic devices in the
the mounting rail is screwed to the
event of overvoltage caused by atmosearthed mounting plate. In addition, the
pheric discharge (thunderstorms) or,
PE contact can be produced by the
much more frequently, switching activity
tension clamp of the MCZ OVP.
(transients) in the network. The PU
modules attenuate strong pulses. In
Application
instrumentation and control circuits, the
attenuated pulses can still cause
The MCZ OVP 24 Vdc CL, an overvoltage
interference in the systems.
protector for current loops, has a fastHence the need for three-level overvoltage switching (10-100 ps) suppression diode
in its output. When overvoltage occurs,
protection terminals, with gas charge
this diode clamps the voltage within the
eliminator, varistors, suppressor diodes
current loop, thus preventing damage to
(TAZ) and decoupling inducers.
the sensor or actuator.
Gas charge eliminators are overvoltage
protection discharges that involve a
discharger. When overvoltage occurs, a
light arc is ignited between electrodes, so
that the discharger passes suddenly (1 s)
from a high-resistance to a low-resistance
range.
Varistors are used for medium and larger
power ratings. Metal oxide varistors reduce
resistance at excessive voltage. The
varistor can become low-resistive within
25 ns, thus discharging the overvoltage.
Suppressor diodes work similarly to zener
diodes but with a high pulse handling
capability with response times of the
order of a few ps.

W
W.38

The MCZ OVP has tension spring connection terminals for fast wiring of instrumentation and control leads. Discharge
takes place directly via a contact to the
mounting rail. The contact is produced
automatically as soon as the MCZ OVP
is snapped onto the mounting rail.

The fine overvoltage protection modules

must be installed in the immediate vicinity
of the devices being protected. The
protective earth of the device must be
connected to the fine overvoltage
protection modules.
A cross-section between 2.5 mm2 and
4 mm2 should be used for routing the
earth leads.
The connections should be kept as
short as possible.
Avoid switching several earth lines in
series.
The earthing systems should be rated
according to VDE 0100, VDE 0185,
VDE 0800 and the Deutsche Telekom
telecommunications directive FBO 14.
Routing lines
The signal lines
should be routed in
the installation by
the shortest route to
the fine overvoltage
protection and then
to the electronic
device. Avoid parallel routing with other
lines and avoid routing protected and
unprotected lines together. (Caution is
required with cable harnesses and cable
conduits!).
If parallel routing is unavoidable, there
should be spacing of at least 0.5 m
between the lines.
Marking the
module
IN

OUT
4

The overvoltage
protective module
is marked with an
arrow or labelled
IN.

The arrow points to the protected side of

the module, i.e. overvoltage is discharged
in the direction of the arrow (see combination circuit).

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Overvoltage protection
Technical dictionary
General data

Requirement for energy systems

Overvoltage protection for
230 / 400 V electricity mains

Eliminators for electricity mains (230/400 V)

are divided into four requirement
categories. Weidmller has three groups of
eliminators in its product range

Eliminators in requirements class B

Eliminators in requirements class C

Eliminators in requirements class D

Eliminators installed for the purpose of

lightning protection equipotential
bonding, capable of coping with direct
strikes of lightning. These eliminators are
tested with a simulated lightning test
current/imp wave form 10/350 s.

Eliminators installed for the purpose of

overvoltage protection in stationary
installations, e.g. distributors. These
eliminators are tested using a rated
leakage current isn, wave form 8/20 s.

Eliminators installed for the purpose of

overvoltage protection in stationary or
mobile installations, particularly for
mains sockets or terminal devices

Basic feed diagram

125 A

160 A
measurement
160 A
160 A

Eliminator (according to draft

VDE 0675 part 6)
B
10/350 2

125 A
KWh 3

125 A

Eliminator (according to draft

VDE 0675 part 6)
C
8/20 s

Insulation coordination is rated for 6 kV

in the 230/400 V mains. According to
DIN VDE 0110, the overvoltage protection must not be lower then class IV.

Insulation coordination is rated for 4 kV

in the 230/400 V mains. According to
DIN VDE 0110, the overvoltage protection must not be lower than class III.

The B-eliminator is used for lightning

protection equipotential bonding when
a lightning eliminator is fitted to the
building.

The C-eliminator is used for discharging

to earth the energy coupled into the
mains feed line. Used in switchboards

16 A

Eliminator (according to draft

VDE 0675 part 6)
D
1.2/50 s
Insulation coordination is rated for 2.5/
1.5 kV in the 230/400 V mains
network. DIN VDE 0110 stipulates that
the overvoltage protection must not be
lower than class II.
The D-eliminator is used for discharging
to earth the energy coupled into the
mains feed line. Used in switchboards
or sub-distributions.

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Technical dictionary
General data

Overvoltage protection

3+1 circuit

Overvoltage protection for TT networks with 3 varistors and one discharger. Prevents voltage
entrainment when varistors are defective.

Eliminator

Protective element which discharges energy symmetrically or asymmetrically.

Disconnect device

Device which disconnects the eliminator from the mains in the event of a fault and indicates that
a fault has occurred.

Ageing

Change in the original rating data caused by interference, operation or unfavourable ambient
conditions.

Requirements class B

Stipulates the purpose of lightning protection equipotential bonding acc. to DIN VDE 0185-1;
see also class 1.

Requirements class C

Stipulates the purpose of overvoltage protection in stationary installations, preferably for use in
impulse withstand voltage category III; see also class II.

Requirements class D

Stipulates the purpose of overvoltage protection in stationary installations, preferably for use in
impulse withstand voltage category II; see also class III.

Response time

Reaction speed ranges from a few s to times in the order of ps, depending on the type and
structure of the protection module.

Asymmetrical interference voltage

Voltage between the electric mid-point and reference potential (earth).

Binary signals

Switching signals with the status on and off.

Lightning surge current Iimp

Defined by the peak current Ipeak and the load Q, when testing according to class I.

Continuous operating current Ic

Current per protection path under operating voltage Uc.

Insertion loss

Attenuation additionally contributed by an inserted four-pole.

EMC

Electromagnetic compatibility.

FI protection switch

If a fault current exceeds a certain limit, the FI switches off within 0.2 sec.

Subsequent current Ir

Current flowing from the mains through the overvoltage protection device immediately after a
discharge.

Galvanic coupling

Interference source and use source have the same impedance (line connected).

Gas charge eliminator

Voltage-dependent encapsulated switch with high current-carrying capacity.

Push-pull interference

The interference source and source of use are connected in series (e.g. magnetic or galvanic
coupling).

Measured voltage limit

Maximum voltage level during application of surges of prespecified form and altitude in testing.

Triggered discharger

A gas-filled discharger ignited by a capacative attenuator at a preset voltage level.

Common-mode interference

The interference source is between the signal wire and reference conductor (e.g. capacitive coupling
or potential increase of physically separated earths).

Frequency limit

Indicates the frequency up to which successful transfer occurs. At higher frequencies, the protective circuit attenuates to such an extent that transfer is no longer possible.

Maximum operating voltage Uc

Highest effective value of ac voltage or highest value of dc voltage tolerated continuously on the
protection path of the overvoltage protection device. Operating voltage = rated voltage.

Inductive coupling

Coupling through two or three live conductor loops.

Insta

Installation enclosure acc. to DIN 43880, suitable for integration of installation distributors.

Ipeak

Peak current of a test pulse.

Isn

Peak value of the nominal leakage current.

Insulation coordination

Peak withstand current capacity of the insulation in installation components according to DIN VDE
0110 part 1.

IT network

Network system with 3 external conductors insulated to earth potential. The PE of the building is
not connected to the network system.

Capacitive coupling

Coupling of interference circuit and use circuit via coupling capacitors caused by a difference in
potential.

Class I

Stipulates the purpose of lightning protection equipotential bonding acc. to IEC 37A/44/CDV; see
also requirements class B.

Class II

Stipulates the purpose of overvoltage protection in stationary installations, preferably for use in
impulse withstand voltage category III; see also requirements class C.

Class III

Stipulates the purpose of overvoltage protection in stationary installations, preferable for use in
impulse withstand voltage category II; see also requirements class D.

Combination circuit

Protection circuit made up (for example) of gas charge eliminator, varistor and/or suppressor diode.

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Combined surge

The hybrid generator generates a 1.2/50 s pulse in idle mode and a 8/20 s pulse in short-circuit. The ratio of peak value idle voltage Uoc to peak value short circuit current Isc is 2 ohms.

Short-circuit strength

Highest non-influenced short-circuit current which the overvoltage protection device can
withstand.

Longitudinal voltage

Interference voltage between active conductor and earth.

Leakage current

Current which flows to PE under rated voltage.

Maximum discharge surge current Imax

Peak value of current 8/20 s during trial run of operational test acc. to class II.

MCZ ovp

Narrow protective terminal with tension spring connection and mounting rail contact for PE.

MOV

See varistor

MSR

Instrumentation and control technology

Nominal discharge surge current In

Peak value of surge current 8/20 during test acc. to class II.

PE

Protection and earthing system to which the energy is discharged.

PU

Overvoltage protection for high pulses in energy systems in installation enclosures.

Transverse voltage

Interference voltage between two conductors of a circuit

RCD

See FI protection switch

RSU

Overvoltage protection on the clip-on base profile with gas charge eliminator, varistor and
suppressor diodes for 6A and 10 A current loops.

Degree of protection of the enclosure

(IP code)

Degree of protection afforded by the enclosure to prevent contact with live parts and to preven
penetration of solid particles or water. Tested acc. to IEC 529 section 7.4

Protection level Up

Indicates the residual voltage measured for an overvoltage pulse at the terminals (preferential value
as highest measured voltage limit). Important parameter characterising the efficiency of the overvoltage protection device.

Protection path

Circuit of the components of an overvoltage protection device; conductor to conductor, conductor to earth, conductor to neutral and neutral to earth are all protection paths.

SPD

Surge protection device

Surge voltage 1.2/50s

Surge voltage with a head time of 1.2 s and a time to half value of 50 s

Surge current 10/350 s

Lightning test current with a head time of 10 s and a time to half value of 350 s.

Surge current 8/20 s

Lightning test current with a head time of 8 s and a time to half value of 20 s.

Radiation coupling

Electromagnetic field coupled in one or several conductor loops.

Suppressor diode

Voltage-dependent, fast-switching semi-conductor diode.

Symmetric interference voltage

Voltage between push and pull conductor (push-pull voltage).

TAZ

See suppressor diode.

TN-Netz

Netzsystem als 4 oder 5 Leiter System, 3 Aussenleiter und der PEN kommen in das Gebude.
PE vom Gebude und der PE vom Netz sind miteinander verbunden.

TN mains

Mains system as 4 or 5 conductor mains; 3 external conductors and PEN are installed within the
building, PE from the building and the PE from the mains are connected.

TT mains

Mains system with 4 conductors. Three external conductors and the neutral conductor are installed within the building. The PE of the building is not connected to the mains system.

Overvoltage

Unwanted continuous or short difference in potential between conductors, or between conductor

and earth, which causes interference or destruction.

Overvoltage protection

Circuit/wiring of an electric circuit to limit the output voltage.

Overvoltage protection installation

Devices and installations included in a system for purposes of overvoltage protection, including
the leads that form part of such equipment.

Overvoltage protection device

Device with at least one non-linear module for limiting transient overvoltages and discharging
surge currents.

Overvoltage protection classes

Classification of electrical equipment according to its voltage strength with reference to the
nominal voltage. EN 50178.

Non-symmetrical interference voltage

Voltage between conductor and reference potential (earth).

Varistor

Voltage-dependent metal oxide resistance; resistance decreases with increasing voltage.

Back-up fuse

Max. fuse to be provided depending on connection cross-section and/or longitudinal decoupling.

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General data

Overvoltage protection

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Technical dictionary
General data

Tools
Cutting

Weidmller uses the term cutting to refer to the severing of

cables, leads and conductors made of copper or aluminium
with a tool specially designed for this purpose.
The requirement for all cutting tools is to perform a straight cut
without deforming the conductor.

Movement of the blades

According to DIN 8588, experts differentiate between shear

cutting, wedge cutting, tearing and breaking.
Shear cutting is used especially for cutting cables, leads and
conductors. Cutting tools with cross blades should perform a
pulling cut without any play.

Squeezing cut

Pulling cut

Cutting can be categorised based on the method used. There

are basically two cutting methods:
squeezing cut,
pulling cut.
In the squeezing cut, the cutting movement is perpendicular
between the tool and the work piece. In the pulling cut, the
cutting movement is diagonal to the tool.

One prime quality feature makes professional cutting tools

stand out from the rest: the shape of the blades corresponds
to, and is optimised for, the specific intended use. The manual
force required for cutting is relatively small, so that the cutting
tool can be used with just one hand.
Another quality feature is cutting sharpness, i.e. the cutting
angle and presence of a facet. A facet produces a specific
slight increase in the cutting angle, increasing the service life
of the blade and the cutting sharpness.
upper
edge

Position of the blades

Position 1

Position 2

In position 1, the blades act directly and along the whole length,
requiring considerable force.
In position 2, the blades cross as in a pair of scissors; the cut
is therefore offset in time and requires less force.

Clean cut

lower
edge

Tools by Weidemller fulfil all the requirements made of

professional cutting tools.

An unclean cut
may look like this:

Insulation
Conductor

Conductor sheared off

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Conductor pulled out

Squeezed cable

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Tools
Technical dictionary
General data

Stripping

Stripping refers to the cutting and removal of insulation.

Compliance with the stripping size must be guaranteed. Neither
the conductor nor the remaining insulation must be damaged.
DIN IEC 352 part 2 (previously DIN IEC 48/290) refers to
stripping faults which must be avoided:

To avoid these faults, it is important for the stripping tool to be

adjusted to the insulation and to the cross-section of the
conductor.
Correctly stripped conductor

Possible stripping faults:

Insulation has not been cut properly

Insulation remnants are still on the stripped

conductor

Cable knives (penknives) should certainly not be used, because

the stripping quality then depends on the manual skills of the
user and even when the user is highly skilled, it is not possibly
to achieve uniform high quality.
Preference should be given to manual tools which adjust
automatically to the cross- section of the conductor. They do
not cause any damage to the conductor during stripping, and
prevent all the above-mentioned stripping faults.
stripax stripping tools guarantee work of constant and
uniformly high quality which complies with the DIN regulations.
The tools are rated for standard PVC insulation. Any PVC
insulation thicknesses deviating from the norm are adjusted
manually. The conductor stopper and integrated wire cutter
allow for highly versatile use of the tools.
Special insulation such as Teflon, silicone and Kapton require
special stripping tools. They strip the conductor using punch
blades.

The conductor insulation has been damaged by the

stripping tool

Individual wires have been damaged or cut off by the

stripping tool

Individual wires have been twisted too hard afterwards

Individual wires are no longer twisted

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General data

Tools
Cross-section diagram:

Crimping wire end ferrules

00.5

Optimum crimp of different cross-sections to serve as a

quality template
Examples of the visual appraisal of a crimp connection with
manual and automatic crimping tools by Weidmller:
The conductor insulation must be pushed into the plastic collar.
The ferrule pipe must be completely filled by the conductor.
Depending on the cross-section, the conductor should
protrude approx. 0 0.5 mm from the ferrule pipe.

Front view:

0.5 mm2

0.75 mm2

1.0 mm2

1.5 mm2

2.5 mm2

4.0 mm2

For cross-sections of
6 50 mm 2, the crimping
shape is about the same.

Faulty crimping connections with wrong combinations of

conductor and wire end ferrule:
It is not possible for a tool to work reliably with every possible
combination of conductors and crimping material.
It is possible that the standard requirements for the crimped
article may not be met, although both conductor and crimping
material comply with the relevant standards when considered
individually. The individual production tolerances of conductors
and crimping materials do not allow every conductor to be
combined with every contact.

Single conductor squeezed off

Single conductor pushed back

The combination of conductors, crimping material and crimping

tool must be coordinated: this is all the more difficult to achieve
given the diversity of products on the market.
Therefore, the material must be defined and the crimping result
tested, ensuring that both the test and (later on) the tool satisfy
the same conditions.
Faults occurring during crimping:

Cracks along the edges and punch impressions

Splitting of the wire end ferrules
Asymmetrical crimping shape
Extreme burrs formed along the edges
Ferrule not filled by conductor
Single conductors pushed back, protruding from the collar
Single conductors squeezed off
Plastic collar damaged by the crimping punch
Conductor insulation not pushed into the plastic collar
Wire end ferrule bent longitudinally after crimping

Cracking at the side edgings

Splitting of the side edges

Cracking at the indentations of

the crimping punch

Note:
The ferrule must not split open after it has been connected in
any Weidmller terminal corresponding to the conductor crosssection (with tightening torques acc. to IEC 60947-1)

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Asymmetrical crimping shape

Asymmetrical crimping shape

One-sided burr formation

One-sided burr formation