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Issue 5 / 2012


We wish you a Merry Christmas and a Happy New Year! 1


6-8 4-5 It is through connections that amazing things happen. For instance, did you know that establishing the Christmas tree as a tradition in the United Kingdom was down to ‘good Queen Charlotte’, the German wife of George III? At the English Court, she transformed the essentially private yewbranch ritual of her homeland into a more public celebration that could be enjoyed by all the members and friends of the Royal Household. She potted up an entire yew tree, covered it with baubles and fruit, loaded it with presents and stood it in the middle of the drawing-room floor. By the time she died in 1818, the Christmas-tree tradition was firmly established in society. Then, in December, 1840, Prince Albert imported several spruce firs from his native Coburg. Soon after, periodicals describing the royal Christmas trees in detail, resulted in the masses setting up such trees in their own homes. The spruce fir is generally accepted today as the best festive tree, with candles and ornaments arranged randomly over them. At Weidmuller, we believe that it is connections that have brought us together with all of you as your Industrial Connectivity partner. Personal connections mean that we can understand your requirements and challenges. Close team connections mean we can develop innovative solutions. Collaboration with scientific and research institutions means we are finding tomorrow’s solutions today. In this issue of Connect UK we hope you enjoy being brought up to date on our latest industrial connectivity solutions, including our RockStar® HighPower 550A, Wemid – our advanced material for connectors, connectivity solutions for Drive Controllers and Regulators, Connectors and Terminals connection systems, PLC Interface Units, Front Adapters and Prefabricated Cables. We would like to take this opportunity of wishing you a very happy Christmas break and look forward to building on our personal connections with you in the New Year. Lesley Young Editor



Field Wiring


Rockstar Highpower 550A


Wemid - our advanced material for connectors


Perfect Fit Connectivity Solutions for Drive Controllers and Regulators

9 - 11

Connection Systems - Connectors and Terminals

12 - 14 ELECTRONICS 12

VPU Surge Protection Devices


PLC Interface Units PLC Interface Units, Front Adapters and Prefabricated Cables selection wizard.


15 15

TOOLS Working safely with electricity

FIELD WIRING RockStar® HighPower 550A Uncompromising power – in clever and safe packaging The RockStar® HighPower modular high-current connector system has been custom-designed for the high demands of traffic engineering applications. The system also meets the requirements of the wind power industry. It consists of one-piece crimp contacts, insulating sleeves, mounting frames and a multi-part die-cast aluminium housing. This modular design offers clear advantages when handling the system. It is possible to wire crimped lines with large cross-sections and to see this process through all the way to the last step. The wiring can be accomplished using standard cable glands.

Optimised shielding


An integrated shield connection in the housing makes the use of standard cable glands possible.

A high-current connector system for demanding applications – designed for up to 550A and 4000V.



Durable laser marking is applied directly onto the housing – enables quick recognition and simple re-ordering.

The proven and maintenance-free crimp connection technology is suitable for stranded, flexible and finely-stranded copper lines up to 240mm².



The multi-part IP68/69K housing is custom-built for RockStar® HighPower. It is highly impact resistant and corrosion proof.

The wiring steps are completely visible: inserts held in a mounting frame are connected to a mounting cover which is then screwed into the body of the housing.


DEVICE CONNECTIVITY Wemid. Weidmuller’s advanced material for connectors

The future of connection technology is here. The trend towards ever smaller electronic products is continuing unabated: • Electronic devices are getting smaller and smaller • The complexity and integration of modules are increasing • Integration density demands higher packing density for PCBs At the same time, the market is making growing demands of the performance and reliability of electronics. Components have to withstand higher ambient temperatures as a result of reduced space between parts on the PCB. In the design phase, this calls for the specification of materials and components of the highest quality. If you want to succeed in the midst of tough competition, you have to master these challenges. Weidmüller can support you with an innovative solution... WEMID


WEMID is a halogen- and phosphor-free special thermoplastic from Weidmüller that displays an enhanced continuous operating temperature of 120°C (by comparison PA 66: 100°C) and improved fire resistance characteristics. The flammability class is V0 (PA 66: V2) in accordance with UL94. Products with an increased continuous operating temperature have the following advantages for the user: on the one hand, the customer can utilise the PCB terminals with the same load current in devices operating in a higher ambient temperature (+20 Kelvin). Or put another way, the same physical size of PCB terminal offers a greater power spectrum and more safety. When seen from the perspective of ‘product liability' the safety aspect takes on particular significance. And on the other hand, with constant ambient temperatures the user can utilise the PCB terminals with higher currents. That means in practical applications that smaller and more economic PCB terminals can be used for the same power spectrum and that more compact devices can be realised. The new PCB terminals made of WEMID fulfil the specifications contained in the RoHS Directive (Reduction of Hazardous Substances). WEMID is qualified for use in railway applications in accordance with NF F 16-101 specifications.


PCB terminals LM 5.0x

The LS 5.08/90° with 90° wire exit is designed for the pitch 5.08. The rated data for the 2- to 12-pole terminals is as follows: 630V/17.5 A (IEC) and 300V/17.5A (UL1059 – E60693). The LS 5.0x is equipped with a compact clamping yoke connection. They are designed to connect conductor crosssections from 0.08 -1.5 mm (IEC) / 28-14 AWG (UL). The clamping yoke is a screw connection technology that is established across the globe. The clamping yoke connection is extremely resistant to vibration, has a high contact force and a constantly low contact resistance.

The LM 5.0x is an extensive family of products equipped with the proven clamping yoke connection for the pitch sizes 5.00 und 5.08 mm. Depending on the version, there are 2- to 24-pole, one, two or three row (72-pole) versions available with different heights. The PCB terminals are available with wire exits of 90°, 180° or 135° and the following rated data: 630 V/17.5 A (IEC) and 300 V/15 A (UL 1059 – E60693). They are designed to connect conductor cross-sections from 0.20 … 2.5 mm (IEC) / 28 …14 AWG (UL).

PCB terminals LL 9.52

PCB terminals PS 3.5 and PM 5.0x

The PCB terminals LL 9.52 have been designed for a pitch size of 9.52 mm and a nominal cross-section of 0.18…6 mm2 (IEC) / 28…10 AWG (UL). And the rated data that flows across the clamping yoke connection is appropriately high:

Both the extremely compact PS 3.5 (3.5 mm pitch) and the PM 5.0x (5.00 and 5.08 mm pitches) are equipped with a pressure clamp connection. The pressure clamp is an economic screw connection technology that is established across the globe. It makes it possible to construct components with a low height. Nominal cross-section and rated data:

1 000 V/32 A (IEC) and 300 V/30 A (UL 1059 – E60693).

PCB terminals LMZF 5.00/135 and 5.08/135

- PS 3.5: 0.08 … 1.5 mm2 (IEC)/ 28 … 16 AWG (UL), 320 V/17.5 A (IEC) and 300 V/10 A (UL 1059 – E60693). - PM 5.0x: 0.13 … 2.5 mm2 (IEC)/ 26 … 14 AWG (UL), 600 V/24 A (IEC) and 300 V/15 A (UL 1059 – E60693).

Enhanced continuous operating temperature of 120°C Electronic and mechatronic devices are becoming ever smaller and more complex. This trend leads to an extremely high assembly density of the integrated PCBs and the correspondingly high temperatures to match. It goes without saying that the devices being utilised must function reliably, even in the face of high on-site ambient temperatures. Finding a solution to this problem begins as early as the design stage of the devices and electronics, placing high demands on the quality of the material and the components to be used. PCB terminals made from the highly heat-resistant insulating material WEMID meet the demands cited above with room to spare.

High levels of planning freedom Designed for the pitches 5.00 mm and 5.08 mm, the PCB terminals LMZF are equipped with a tension clamp connection. The 135° wire exit ensures that the conductors can be comfortably connected everywhere on the printed circuit board. The user can choose between versions with and without a lever to open the terminal point. Nominal cross-section and rated data: 0.13 … 2.5 mm2 (IEC)/ 26 … 14 AWG (UL), 630 V/24 A (IEC) and 300 V/15 A (UL 1059 – E60693). The tension clamp connection technology is a byword for rapid, maintenancefree wiring with high levels of contact reliability. With the PCB terminals made of WEMID, Weidmüller is offering its customers a programme of products that is distinguished by its suitability for a wide spectrum of applications and enormous flexibility PCB terminals made from WEMID for increased safety and performance in higher ambient temperatures.

It does not matter which family of PCB terminals a Design Engineer wishes to use in their application, at Weidmüller they always retain high levels of planning freedom. This is supported by the standard colours: orange, grey, green and black as well as the conventional pole numbers. Equipment can be marked on-site for identification using strips of terminal markers or supplied ex-works with markings printed on them directly. PCB terminal families equipped with a pressure clamp or clamping yoke connection are fitted with a ‘plus/minus' screw as standard for reliable operation and transmission of the required torque. Conventional flat-bladed or Pozidrive Z cross-headed screwdrivers can be used at the user’s convenience for screw connections with a ‘plus/minus’ screw. That means that ‘plus/minus’ screws also allow power-operated screwdrivers to centre more easily.


DEVICE CONNECTIVITY Perfect Fit Connectivity Solutions for Drive Controllers and Regulators

Semiconductor technology for power electronics has progressed at a steady pace in the last few years enabling more complex drive controllers to be manufactured, e.g. for rotational speed controllers or for precise positioning systems. So it’s more important than ever to take advantage of connection technology that you can trust now and in the future. We specialise in industrial connectivity; our connectivity solutions for the power electronics sector are backed by our


comprehensive, real-world expertise. We understand the extremely demanding requirements for the servo-controllers and frequency inverters that are common in this business. Voltages of 400 to 690V (according to IEC) and 600V (according to UL), and up to 1000V in DC circuits, are not uncommon for such equipment. That is why you require high current-carrying capacity implemented in the most compact space possible. We can provide superior connectivity solutions to meet these challenging requirements.


Reliable device connections are essential to meet the maximum power and voltage requirements found in power electronics applications. For that you need products with many features which ensure maximum safety and reliability. A particular design of the mating profiles makes it impossible to accidentally plug the wrong connectors together. The connectors can also make use of additional attachment mechanisms such as latches, interlocks or screws. You can select the spring or screw connection for the wire, depending on your application requirements. To further support proper on-site wiring, one can print the products with customised wire assignment labelling. Many products provide plug-in connectivity solutions for power electronics applications and state-of-the-art drive systems. The

current range sets a new standard – with increased safety and innovative details such as a pluggable shield, integrated signal contacts and onehanded operation. The standard connectors and IT-mains connectors are suitable for wire cross-sections of 2.5mm², 6mm² and 16mm. Some products provide a sturdy, direct-connect solution to deal with extreme current and voltage requirements for many power electronics applications: such as solar inverters, frequency converters, servo-controllers and power supplies. They come in 10.16mm, 12.7mm and 15.0mm pitches, and can connect wires up to 50mm². Finally, a few products are a universal solution for feeding currents of varying magnitudes through device panels. Often they are suited for connecting wires from 4mm² to 95mm².

2. Intermediate circuits (DC-Link)

3. Motor connections

A touch-protection shield on both sides of the plug-in connection helps to minimise the risk from high inverse voltages. This means we are in full compliance with device approval guidelines as laid out in IEC 68100-51. The female headers, when used together with the correct male plugs, can provide 3 mm of touch protection on both sides of the unplugged connection. More standards compliance, less compromise. The features built into these connectors simplify your design-in and approval processes and ultimately make your operations more reliable. For non-pluggable connectivity solutions, we recommend PCB terminals in 10.16 mm, 12.7 mm and 15.0 mm pitches, for connecting wires up to 25 mm², or device feed through terminals for 4mm² to 50mm². When working with high voltages, the spacing between poles for the PCB terminals and device feed through terminals can be widened.

This interface typically requires connections for the motor voltage, internal temperature sensor and possibly the mechanical brakes. Depending on the application, a connection to an encoder or resolver may also be required. The hybrid motor connector needs only one plugging operation to simultaneously connect power, signals and cable shielding. This helps you to save space on the circuit board and on the housing’s exterior. A onehanded, auto-interlock mechanism speeds up installation and maintenance procedures. It is easy to handle and interlocks automatically – even in hard to reach areas. Currently there is only one manufacturer to provide special PCB connectors for devices connected to IT-type power grids. PCB terminal blocks (in 10.16 mm, 12.7 mm and 15.0 mm pitches with wire connections up to 50 mm²) offer non-pluggable connectivity solutions. For panel feed through bushings, we recommend using device feed through terminals with 4 mm² to 95 mm² wire connections.



5. Positioning feedback and network connections

Safety switching devices (such as emergency-stop switches, safety light curtains and door switches) communicate closely with drive controllers. They protect both the operator and machine ensuring that connected drives can be stopped immediately when required. The connectors, in 5.08mm pitch and with either screw or “PUSH IN� wire termination ensure reliable connection.

Industrial, quality data connections are essential for providing reliable data transmission. These components feature a much higher level of quality and reliability than is normally specified for a conventional office PC. Weidmuller product lines include IP67 solutions for industrial network connections and positioning feedback which are recommended for positioning feedback and encoder connections. Over moulded cable assemblies are also available as an alternative. A variety of RJ45 connectors with crimp or IDC wire termination in accordance with Cat. 6A, class EA and with protection classes ranging from IP20 to IP67 for every network connectivity requirement are also available.

6. External I/Os

7. IP65 modules

Servo-amplifiers require input interfaces for home switches, limit switches, etc. They also require output interfaces for any solenoid valves, conveyor controllers and a foreign machine interface (FMI). The connection voltage depends on the application and lies between 12 and 24VDC or up to 240 VAC. Pluggable connectors are optionally available with a screw flange or release latch to ensure an even stronger attachment. The connectors can be printed so that the connections are clearly labelled and cannot be miss-mated. For SMD-assembled circuit boards, the wire connections are available in reflow-compatible SMT variants. The smallest plug-in solution is available in 3.5mm pitch that features an integrated signal display and a built-in cross-connection for supplying power to any connected sensors and actuators. They are the perfect choice for I/Os from 10 to 30V. There are other pluggable versions, for pitches up to 5.08 mm, which can be combined on the circuit board with the reflow-compatible male header when needed.

Decentralisation of Power Electronics Modules assists with the simplification and acceleration of plant planning and maintenance projects saving time and money. The prerequisites for these modules are a rugged housing and high protection degrees. It is crucial that the connection system also supports a simple pre-installation method, fast initial commissioning and convenient servicing. Some Control housings are built from polycarbonate that is extremely stable when exposed to flame. They are perfect for use as enclosures for electronics, or with switching and protective equipment. The power supply has an integrated power bus; it can be installed quickly and smoothly using conventional round cables. The cables do not need to be cut or specially prepared for the connection. Hinged seals allow the plug wires to be inserted quickly. The sensors, actuators and data bus are best connected using M12 or RJ45 connectors. IP65 connectors (in accordance with ISO 23570) are available for the power outlet. They can be used with unshielded or shielded motor cables.


DEVICE CONNECTIVITY Connection Systems - Connectors and Terminals

Below is a description of the benefits and field of application for several electrical connection systems.

Clamping Yoke Screw Connection The clamping-yoke connection is the most used screw connection in the world. Steel clamping yokes made by using a stamping and bending process guarantee a vibration proof clamp connection. When the screw on the clamp is tightened, there is a counter effect in the clamping yoke's threaded area which prevents the connection from accidentally loosening. As the screw thread is on an inclined plane, there is a force gain created and a very high clamping force is achieved. Hardened steel with optimal corrosion protection can be used for stability and security, and copper alloys in the contact area for good electrical conductivity. Benefits • The screw connection guarantees a globally accepted, vibration proof, and maintenance free connection. • A large conductor clamping area is covered. • The "Wire Ready" technology ensures that the terminal points are fully open at delivery, even after being transported world-wide • The "Wire Guard" protection mechanism prevents accidental insertion of the wire underneath the clamping area, which can be dangerous, and it protects against hidden faulty contacts • The flat clamping yoke also enables the clamping of very small crosssection wires Field of Application The standard connection for applications in industrial environments with the highest requirements for reliability even under harsh conditions.


DEVICE CONNECTIVITY PUSH IN Spring Connection The PUSH IN spring connection with direct plug-in technology allows the fastest wiring process: the stripped or prepared wire is simply pushed into the terminal point as far as it will go and the connection is finished. Operating the release lever is only required with very standard wire or to release the connection. The stainless steel spring ensures a high contact force between wire and the tinned copper busbar. A stainless steel cage enclosure prevents subsidence in the contact area. To prevent any drop in clamping force, plastic parts are deliberately not used. Benefits • Fast, toolless wire connection with direct insertion technology • The stainless steel spring results in a vibration resistant connection • Higher resistance to wire pull-out than in a tension clamp system • Constant conductor clamping force independent of the operator • Operator error is reduced using a color coded and intuitive actuator • Wire feed and the operation are aligned in the same direction which permits a compact equipment design Field of Application The default choice for operation in the field, it permits speedy wiring and, combined with its small size, its intuitive use is also advantageous even in environments with severe vibration.

TOP Screw Connection Terminal with Pull-Effect In the traditional case, the screw is always at a right angle to the conductor outlet direction, the TOP connection however, allows wire insertion and the screw orientation in the same direction. The TOP connection produces the greatest possible packing density in the terminal area. The ”pull effect“ ensures that the connected wire is pulled in to the clamping point, producing a secure contact. Benefits • The “pull effect” pulls the wire into the terminal point. Problems with clearance and creepage distances are avoided. • Wire feed and the operation are aligned in the same direction, which permits a compact equipment design • The minimum installation height results in an extremely high packing density Field of Application Housing design or installation requirements such as PCB slots, that do not allow a right angled screw operation for reasons of space.

Tension Clamp Connection The pre-tensioned tension clamp made from high quality rust and acid resistant steel pulls the wire against the galvanised copper busbar, resulting in a permanent and vibration resistant connection. The spring can be opened with a screwdriver. The wire is fed through the wire guide into the spring cage. When the screwdriver is removed, the wire is clamped. The surface-treated busbar ensures low contact resistance and a high resistance to corrosion. Benefits • Constant conductor clamping force independent of the operator • Widespread connection technology • Simple operation using a screwdriver or the integrated release lever Field of Application Fast wiring with a constant clamping force, even in environments with severe vibration.


DEVICE CONNECTIVITY Crimp Connection The crimp connection method provides an affordable solution with preassembled female plugs that is also appropriate for large batch jobs. The crimp contacts can be attached using hand tools or with a crimping machine when producing large batches. The contacts then only need to be locked into the housing provided. For fully automated processing, taped crimp contacts are available. Benefits • Rapid, fully automated preassembly of connectors is possible • Long lasting, positive connection methods • Minimal contact resistances • The conductor connection is extremely thermal shock and vibration resistant Field of Application Applications that combine fully automatic and factory oriented processing steps with the actual field wiring - works even in environments with severe vibration or temperature fluctuations.

Leaf Spring Screw Connection The leaf spring screw connection is the oldest method on the market for connecting a conductor. The leaf spring below the screw reliably prevents damage to the conductor when the clamp screw is tightened. The leaf spring is a simplified connection yet suited for the requirements of building automation connection technology. Benefits • Cost effective alternative to the clamping-yoke connection • A particularly simple connection solution suited to less demanding environmental conditions. • High power density in a small footprint Field of Application Applications with less demanding environmental conditions and narrow installation space.

Flat-Blade Connection Flat blade connections are a widespread connection method in accordance with DIN 46247. This technology connects preassembled, insulated and noninsulated cable lug sleeves by simply insertion of the cable lug connector on a standard terminal block. Benefits • Fully automated, preassembled wire bundles are possible • Can be used with 2.8 and 6.3mm flat blade receptacles • Suitable for insulated and uninsulated versions. Field of Application Suitable for applications where pre-assembled cables neeed to be fitted quickly into the PCB


ELECTRONICS Your infrastructure needs protection from lightning and surges. We have protection systems that are future-proof

New VPU surge voltage protection devices from Weidmüller Weidmüller’s new comprehensive lightning and surge protection VPU series fulfils requirements for protection levels 1, 2 and 3 for power networks. This means full compliance with the current IEC 61643-11 and the future EN 61643-11 standard being introduced in 2013. As well as the increase in specification limits, the introduction of the new IEC/EN 61643-11 standard places a high degree of significance to all-round, reliable, surge protection. Our answer to these new requirements is the new VPU lightning and surge protection series. Based on a combination of varistor and gas discharge technology, the VPU product series is primed for the future but already meets the conditions of the new international standards, so delivering sustainable protection for buildings and plant infrastructures. The VPU series enables users to not only secure their facilities, but also their planning process. Due to its conformity with standards dating back at least five years, users of the new VPU lightning and surge protection can minimise the iterative steps for planning in accordance with the application standard I EC61643-12 and the associated re-designs.


Securely mounting The arrester can be heard and felt locking into the base. This enables it to comply with the exacting requirements of vibration resistance set by wind turbine plant manufacturers. Rapid status messaging The remote signalling contact with Push In connection can be quickly connected and provides reliable status information. Clear overview The large, centred status window provides highly visible information on the status of the protective function. Faster to assemble The optimised mounting rail clip enables easy and quick assembly and removal, without the need for tools. Flexible positioning in the control cabinet According to IEC 62305, the line path from the surge protection module to the PE connection may only be 50 cm. The fact that you can rotate the base through 180° means that you have the highest degree of flexibility during installation, without impacting on overall visibility. Visit for more information

ELECTRONICS PLC Interface units, Front Adapters and Prefabricated Cables Universal solutions for PLC I/O Cards Aimed at reducing costs, and to save space and time in the construction of electrical cabinets, the universal cabling system for PLCs is provided as an effective alternative to end-to-end cabling design. The increasing complexity of machinery and facilities in industry means that attention is being drawn to the resulting rise in the costs of wiring. Traditional end-to-end cabling between the PLC and the field components has many drawbacks: • High assembly costs: Time-consuming routing and assembly of connecting leads. • The risk of wiring mistakes increases in proportion with the number of individual wires at one end. • Individual wires occupy a considerable amount of space in the cabinet. • High installation and implementation time. • High labelling and documentation workload Weidmüller offers a complete line of pre-assembled cables, together with a range of compact interfaces, to connect with the main commercial PLC manufacturers: Siemens, Allen Bradley, Omron, Schneider, Mitsubishi, ABB, GE, Honeywell and Emerson

Pre-assembled cables The connection using pre-assembled cables drastically reduces the connection work between the PLC and the field components. Each pre-assembled cable has the following features: PLC connector: The original manufacturer’s connector is used to guarantee compatibility. Interface Connector: 3 types of connectors are used according to the interface they connect to. • Ribbon cable connectors - which are supplied with a hood to protect them from cable extraction forces and ensure secure and reliable connection. • Very sturdy RSV connectors that allow working with high voltages of up to 230 V.

• SUB-D connectors, where the wire screening for analogue signals is connected directly to the metallic body of the connector to minimise the effect of electromagnetic interferences Cable: A multi-pole 0.25 mm² cross-section wire is used. This is also shielded for analogue signal cables. Each of the individual wires is identified by means of a colour code according to DIN 47.100.

PLC interfaces The interfaces are used as an interconnection element between the control and the process. These interfaces, with a compact design, provide different functions such as LEDs, fuses, disconnections or relays. The range includes passive input/output interfaces for digital and analogue signals and relay boards to isolate the input and output signals. The Weidmüller universal interfaces for the PLC have an extruded profile to secure the PCB and clip-on feet for locking on either TS 32 or TS 35 DIN rail. These interfaces are universal: the same interface can be used by different PLCs from different manufacturers. The passive interface range has been designed for 4, 8, 12, 16 and 32 signals in tension clamp or screw connection The RSM family, available in 8, 12 and 16 relay versions in compact form (6 mm relays) or standard (RCL relay) and include additional features such as fuse protection. In addition, relays can be replaced by Weidmüller SSR modules: Advantages of the system The combination of pre-assembled cables and the interfaces allows the final connecting system to be: Safe • It excludes the risk cabling errors Fast The use of pre-assembled cables means there are real savings in time: • During design, thanks to the selection guides. • During assembly. • During commissioning. • During fault finding. Reliable • No cabling errors. • Clean cabling in cabinet (multi-pole cables instead of single cables).

Flexible • A multitude of input/output interfaces. • Variable cable lengths. • Expansions can be made without any problem. • Flexibility thanks to the simplicity of interchanging and diverse input/output interfaces. • Easy migration to another system, simply by changing the pre-assembled cable. Compact • More space in the cable trunk. • Narrow modules. • No terminals.


ELECTRONICS PLC Interface units, Front Adaptors and Prefabricated Cables selection wizard.

The quickest and easiest way to select your cable and interface units. When you are planning your new design it is important to select the correct components from the beginning. The on-line product selection wizard ensures that you are confident in your product selections with just a few clicks of the mouse. You start by selecting the PLC Manufacturer, the number of channels required and finally the manufacturer’s card name. Once you have chosen the correct card you can pick the PLC Interface unit by selecting from the drop down menu


options, the number of wires in the system, LED, fuse, disconnect and connection technology requirements. The resulting options will be highlighted from which you can make your PLC Interface choice. Lastly you can click on the corresponding PLC to Interface cable length to complete your selection process. From this you will have your parts list and you can download the relevant datasheets as required. See how it works at

TOOLS Working safely with electricity. Sadly even today many experienced electricians are killed or seriously injured as a result of electrocution. When working with electricity day after day for many years complacency can creep in and the dangers can be taken for granted and live working is often carried out to save time rather than ensuring the supply is safely isolated. Other dangers include where a disconnection device has not been securely padlocked off and warning signs not placed and the supply has been switched back on by someone else. Work on or near live conductors is detailed within Regulation 14 of the Electricity at work regulations which basically requires that live working should be avoided unless it is unreasonable in all circumstances for the conductor to be dead and even then that precautions such as the safe isolation procedure and personal protective equipment has to be used.

The safe isolation procedure has four main steps: Step 1 Check with the occupier / occupant that it is safe and acceptable to disconnect the supply. Identify correct disconnect device and lock off with suitable lock and place a suitable warning notice.

(b) Excessive current drawn through test probes, leads and measuring instruments. This happens when a multi-meter is set to the wrong function, e.g. set on a current or resistance range when measuring voltage. “ For two pole testers this guidance details that testers should have; • Minimum of exposed metal tip. (2mm recommended)

Step 2

• Have finger barriers to guard against in-advertent hand contact with live conductor.

Prove the correct operation of a suitable voltage detector with a proving unit or a known supply.

• Clear voltage rating

Step 3 Using a suitable voltage detection instrument check to ensure there is no dangerous voltage present on any of the circuit conductors to be worked on. Step 4 Prove the voltage detection instrument again against a proving unit or a know supply to prove that it was functioning properly when the circuits were tested for the presence of voltage. If the voltage detection instrument has been proven again in step 4 to be operating then work can then commence. Equally as important to following safe working practices and procedures to avoid accidents is the use of recognised safe voltage detection devices to test the absence of dangerous voltages. Voltage detection instruments such as voltage sticks, Neon screwdrivers and multi-meters are NOT recognised as suitable voltage detection devices for the purposes of the safe isolation procedure. The procedure for testing the absence of voltage should be carried out by the use of a two pole tester or proprietary test lamp as recommended by the health & safety guidance note GS38. Below are two of the main causes of accidents with test equipment that are pointed out within the above HSE guidance note; (a) Poor insulated test probes (typically having an excessive length of bare metal at the contact end) accidentally bridging a live conductor and adjacent earthed metalwork; or

• Current limiting and or fuse protection • Robust, flexible, well insulated and suitably sheathed test leads to protect against mechanical damage. • Colour coded leads so that clear identification can be made. In addition to this the revised standards for these types of testers (i.e. DIN VDE 0682-401:2011 and DIN EN-61243-3:2010) call for a variety of changes, which amongst others affect the protection class, the voltage category, climatic conditions and EMC compliance. Weidmullers new two pole testers exceed the minimum requirement of IP54 rating as required by the revised standard and are rated at IP65. This gives them complete protection against the ingress of dust and protection against jets of water projected from any direction. The two pole voltage testers Digi Check Pro, Digi-Check, Multi Check, Combi-check Pro and Combi Check are CAT IV 600V instruments, while the Master Check belongs to the Category CAT IV 400V. This makes them suitable for use on testing low voltage systems according to their respective voltage rating. Moreover, the new voltage testers are all temperature resistant from -15°C to 45°C and meet the requirements of electromagnetic compatibility tests. Our UK specific testers with 2mm probe tips meet or exceed both the above health and safety guidance GS38 note and the new standards for these types of testers. Don’t be another statistic Follow safe working practices and use a recommended tester from Weidmuller a name you can trust for tools! Further reading and information on safe working practices and test equipment can be sourced from the Electricity at work regulations, the Health and Safety Executive (HSE), Electrical safety council and approved bodies such as the NICEIC and the ECA.

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Weidmüller - Partner in Industrial Connectivity As experienced experts we support our customers and partners around the world with products, solutions and services in the industrial environment of power, signal and data. We are at home in their industries and markets and know the technological challenges of tomorrow. We are therefore continuously developing innovative, sustainable and useful solutions for their individual needs. Together we set standards in Industrial Connectivity.

Christmas Closing: Please note that our office will be closing on Friday 21st December and we will be re-opening at 08:30 on Wednesday 2nd January. The last date to place an order for ‘guaranteed’ 2012 delivery is Wednesday 19th December. Any orders received after then will be classed as 2013 orders. Our E-shop will remain online during the shutdown period. Let’s connect!

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Field Wiring


Weidmuller Ltd. Klippon House Centurion Court Office Park Meridian East Meridian Business Park Leicester, LE19 1TP Sales: Technical:

0845 094 2006 0845 094 2007

Connect UK Issue 5  

Weidmuller UK Newsletter

Connect UK Issue 5  

Weidmuller UK Newsletter