Connection of cables and insulated wires

Content
General
Methods of connection
Core end sleeves
Soldered connections
Terminal blocks
Equipment terminals – Busbar connections

General
The reliability and safety of an electrical installation depends greatly on the satisfactory condition of the contact
connections. For this reason, terminal connections should have sufficient and secure contact pressure, and
soldered connections should contain no impurities.
Always tighten contact screws with a screwdriver which fits the slot correctly. Use an electric screwdriver with
adjustable torque for terminal blocks with screwdriver guides. Tighten contact screws with hexagonal heads
(e.g. terminal blocks type 8WA2 610) with a socket wrench. After assembly and testing of the electrical
installation make random checks (max. 5%) of the contact screws of terminal blocks and of equipment with
torque to Fig. 13 and 14.

This is not required for shop-finished components and equipment.

Plastic insulated solid wires (also cable cores) with cross-sectional areas from 0.5 to 4 mm2 should only be
stripped with a stripax stripping tool and from 6 to 16 mm2 only with a thermal stripping tool (see MS 295).
Nickling of the conductor must be avoided (risk of breakage).

Methods of connection

Terminal Copper conductors in mm2 Al conductors in mm2

connection
Solid Wire Stranded Multi- Fine or Solid wire Stranded wire
wire stranded very-line
wire to AWG stranded
(mainly wire
outside
Germnay)
Connection 0.4 mm dia 16 – 240 0.2 – 240 0.5 – 16 2.5 – 16 25-240
to modular No special
and 16 mm2 No special Core and Scrape clean weld solid,
channel requirements sleeve No
mounting No special Requirements special And grease file clean and
terminal requirements grease
blocks and Requirements Immediately*** immediately***
pilar Above or crimp on pin
terminals 25*** cable lug
with pinch (terminal posts)
protection If required
(for details
see fig. 13,
19 and 28)

Not permitted : Soldering

Connection 0.4 mm dia. 16 – 240 0.2 – 1.0 0.5 – 16 2.5 – 16 25
to pillar – 10 mm2
terminals slip on end No special Crimp on end Crimp on scrape clean weld solid,
without sleeve 1.5- end
pinch 16 No special Requirements Sleeve 1.2 – and grease fine clean and
protection requirements 16 Sleeve grease
(for details immediately*** immediately***
see fig. 19) No special or crimp on pin
Avoid : cable lug
Requirements (terminal posts)
Bending into
loops
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Not permitted : Soldering Above 25***

Connection 0.4 mm dia. 16 – 25 0.2 – 16 2.5 – 16 25
to – 16 mm2
terminals No special Crimp on end sleeve (in Scrape clean Weld solid,
with arched No special special cases use a pin-type
washers, U Requirements cable lugs And grease File clean and
clamps, Requirements grease
raised -- Immediately*** immediately***
corners Avoid : or crimp on pin
and V _____________ Avoid : cable lug
grooves Bending into (terminal posts)
loops Not 25 Bending into
(for details permitted : loops
see fig. 19) crimp on cable lugs
Crimping of
cable lugs* __________
Note permitted : Soldering
Connection 0.4 mm dia. 16 – 25 0.2 – 16 2.5 – 16 25
to terminal – 16 mm2
posts or Use arched Crimp on Crimp on end sleeve or pin Scrape clean Crimp or weld
screws up washer cable cable lug (with arched on
to M6 Avoid : washer) And grease
Lugs Cable lugs.
(for details Bending into _____________ Immediately***
see fig. 22) loops Not Avoid : As appropriate
permitted : 25 (with arched
Soldered
Crimping of cable Crimp on cable lugs washer)
cable lugs
Lugs _____________ Avoid :

Not permitted : Soldering Bending into

loops
Connection 0.4 mm dia. 16 – 300 0.2 – 10 2.5 – 16 25 – 300
to terminal – 16 mm2
posts or Use arched Crimp on Crimp on end sleeve (use Use arched Crimp or weld
screws M8 washers for cable arched washer for flat lugs washer for on cable lugs.
or larger flat lugs or or copper bars) connection to
(for details copper bars Lugs flat lugs or As appropriate
see fig. 23) _____________ aluminum bars
Avoid : Avoid :
16 – 300 Avoid :
Bending into Soldered
loops Not cable Crimp on cable lugs Bending into
permitted : loops
Lugs _____________
Crimping of
cable lugs Not permitted : soldering

Connection 2.5 – 16 16 – 240 0.2 – 16 2.5 – 16 25-300

to clamp
terminals No special No special Crimp on end sleeve Scrape clean weld solid,
(for details
see fig. 29) Requirements Requirements Above 25 ** And grease file clean and
Not for grease
cable _____________ Immediately*** immediately***
clamps in or crimp on pin
high- Not permitted : Soldering cable lug
voltage (terminal posts)
plant

* For exception see MS 300

** Wrap with 0.3 mm copper sheet or strip or use end sleeve manufactured
by Dr. Peters or pin cable lugs

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

*** Use only acidfree vaseline for greasing e.g. Centoplex 24 DL (Messrs.
Kluber) or Alvania P3 (Shell)

Fig. 1

Types of conductor and methods of connecting to various types of terminal

Conductor design

Type of Solid Stranded wire Stranded wire to AWG Fine-stranded wire Very-fine-
conductor Wire (mainly outside Germany) stranded wire
According to re, M, sm - f fst
VDE, DIN2) se3)
According to Solid, Stranded/compactNon flexible/semi flexible flexible (litze) flexible
ANSI, BS1) single
German massivMehrdrahtig flexibel (Litze) flexible hochflexibel
nomenclature
Conductor 0.4 16 – 240 To, 1.5 To 16 0.5 – 240 25 – 120
cross- mm Q
sectional area to 16
in mm2
Diameter of 0.4 – 1.7 – 2.24 0.05 – 0.25 0.3 – 1.6 0.2 – 0.5 0.15 – 0.2
individual wire 3.6
or strand in
mm
Example of Fixed Fixed cabling Moving parts In place of fine Mobile loads and Highly flexible
application cabling and modules in stranded wire connecting cables
industrial (flexible) which move e.g. due Connections,
electronic outside to shock or vibration hand welding
equipment Germany cables, shorting
or jumper leads

Fig. 2 1) ANSI = American National standard, BS = British Standard

Definition of types 2) VDE = Verband Deutscher Elektrotechniker, DIN = Deutsche Industrie –

of conductor and Norm
design
3) only for Al

Core end sleeves

Use end sleeves when connecting solid wires up to 1.0 mm2 crossectional area to terminals without pinch
protection. On the other hand flexible (fine stranded wire) conductors up to 16 mm2 must always have an
end sleeve for connection to terminals with or without pinch protection. End sleeves for conductors up to 16
mm2 should only be crimped with a crimping tool (made by weidmuller). Side cutters, round-nose pliers or
similar tools must not be used to put on end sleeves. Whenever possible, use pin-type cable lugs (made by
Grote + Hartmann) for cross-sectional over 25 mm2.

According to DIN 46 228, Sheet 1, end sleeves are available inone length for conductor cross-sectional areas of
0.5 to 0.75 mm2, in two lengths for 1 to 4 mm2, and in three lengths for 6 to 16 mm2. For fine stranded wires
of 25 to 185 mm2 use end sleeves made by Dr. Peters.

Co-ordinate the conductor cross-sectional area, the end sleeves size and the crimping dies as shown in Fig. 5.

To crimp the end sleeves on the conductor, strip the insulation to that the bare conductor complete with end
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sleeves in the lower insert and press the crimp tool home. If necessary shorten the crimped end sleeves with
side cutters.

1. End sleeve

2. End of conductor must be visible

3. Identification number of crimp tool

insert

4. Core insulation

5. Conductor

6. Crimp tool insert

Fig. 4
Fig. 3
PZ3 crimping tool for conductor
PZ2 crimping tool with interchargeable cross-sectional areas from 0.5 to 6
crimping dies for conductor cross-sectional mm2 (weldmuller)
areas from 0.5 to 16 mm2 (weidmuller)

End sleeves according to DIN 46228, Sheet 1 One fine- One solid
Nominal Length Inside Outside stranded wire
cross- diameter diameter wire
sectional mm (DO NOT
area mm Mm Mm2 CRIMP)

mm
0.5 6 1 1.3 0.5 0.8 mmq
0.75 6 1.4 1.7 0.75 1.0 mm2
1.0 10 1.6 1.9 1.0 1.5 mm2
1.5 7, 10 1.8 2.1 1.5 -
2.5 7, 12 2.3 2.6 2.5 -
4 9, 12 2.8 3.2 4 -
6 10, 12, 15 3.6 4.0 6 -
10 12, 15, 18 4.5 4.9 10 -
16 12, 15, 18 5.8 6.2 16 -

Fig. 5

End sleeve data (weidmuller) and information relating to end sleeve size, solid or fine-stranded wire for the
weidmuller crimping tool

Soldered connections up to conductor cross-sectional areas of 2.5 mm2

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

Soldered connections should only be made with 1 mm dia. Rosincored solder wire type L-Sn50Pb Cu or L-
Sn60Pb Cu 2 (made by Elsold, D-3380, Goslar). Do not use soldering joints or overheating, select the soldering
iron power according to the sum of the conductor crosssectional area and the cross-sectional area of the
soldered connection (Fig. 6).

In order not to affect live circuits containing semiconductors the soldering iron for these applications must be
insulated and used with an isolating transformer or at a low voltage as laid down in VDE 0100.

Avoid vibration (e.g. from shock loads) as well as tensile and bending stresses at the soldered joint (risk o
breakage). Secure single conductors and bundled conductors about 60 mm from the soldered joint in order to
avoid wire breakages in equipment subjected to vibration or transport by road or rail.

Power of soldering iron Possible applications* Sum of cross-sectional

in watts areas of coductor and
soldered connection in
mm2
15 Parts on printed circuits Up to 1
25 or 30 Conductor connectors or 1 to 2
SIMATIC® socket
connectors with
conductor diameters from
0.5 mm to 0.8 mm
40 or 50 Medium sized soldering 2 to 3.5
lugs with conductors from
1 mm2 to 1.5 mm2
70 or 80 Marshalling racks with 3.5 to 5
conductor diameters from
0.5 mm to 0.8 mm
90 Soldering terminal strips 5 to 7
with conductors from 1
mm2 to 2.5 mm2

• For special soldering jobs (e.g. commissioning) use the next lowest soldering iron power where possible

® Registered Trademark

Fig. 6

Soldering iron powers for various standard applications

Fig. 7b

Fig. 7a Placing conductor on

Bending conductor round
terminal (when no
soldering hole or soldering
slit is provided)
terminal (when the cross-
sectional area of the
conductor is too large to
isnert it into the soldering
hole)
Fig. 7c
Inserting conductor
(recommended for links)

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

Fig. 7d
Inserting conductor into
terminal block with
soldering lug (up to 1.5
mm2)
* Where soldered
connections are very
close together the end of
the conductor should not Fig. 7f
product more than 1 to 2
mm from the joint Soldered connection on
plug connector

Fig. 7e

Inserting conductors
(diameters exceeding 0.8
mm)

Solid conductor of up to 2.5 mm2 cross – section area

Soldering lugs or conductor ends which have been cleaned for soldering and which are metallic bright must not
be touched by hand. Because of the risk of oxidation, solder the conductors as soon as possible after stripping,
i.e. at least on the same day. Insert or hook the conductors to be soldered in soldering lugs provided with holes
and either bend them round or place them on soldering lugs without holes (Fig. 7a to 7f).

After bending the conductor ends round soldering lugs, firmly squeeze the ends with pointed pliers or flat nose
pliers. The pliers must not have sharp edges. Do not twist or bend the soldering lug to enable the conductor end
to be more easily inserted. To solder, place the greatest possible contact area of the soldering iron against the
soldering lug and heat the soldered joint well. Feed the solder from the opposite side (not directly at he soldering
iron) until the conductor to be soldered is embedded in solder. Do not apply any more solder to the joint than is
necessary to barely embed the conductor. A good soldered joint should have a silvery gleam.

During soldering (max. 2 s) observe how the solder flows; it must flow well at the conductor and lug (fig. 8).

Fig. 8

Example of a good and a poor soldered

joint

With closely spaced soldered connections always start with the rearmost connection in order that the insulation
of the conductors lying in front is not overheated. Do not allow the solder or the flux (resin) to touch the
insulation of the soldering lug. The clearance between the conductor insulation and the soldering lug should not
be less than 1 mm and not greater than 2 mm. Do not remove the remains of unevaporated flux (rosin) from
the edges of the soldered joint.

Wipe the soldering iron frequently on a damp cloth (not woolen) during the soldering work. The soldering iron tip
should be tinned on both sides. To avoid damaging the conductor insulation do not adjust or straighten soldered

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conductors immediately after soldering. Do not use adjusting pliers or tweezers with sharp jaws or serrated
surfaces to adjust or straighten the soldered conductors whether they are hot or cold.

When soldering SIMATIC or other semiconductor elements do not damage the inside of the components by
overheating the soldering lug or soldered joints. Use soldering irons with the appropriate power as specified in
Figure 6.

The second hole in the lug serres to dissipate the heat and must not be soldered (danger of lug becoming
unsoldered from conductor path Fig. 7f).

Litz and fine-stranded conductors of cross-sectional areas up to 6 mm2

Solder joints with fine or extra-fine stranded conductors either directly or after fitting crimped pin cable lugs, as
shown in Figs. 9 to 12.

Before directly soldering litz conductors or insulating wires, slightly twist and tin the ends immediately after
stripping the insulation in order to keep the individual strands together.

Depending upon the type of stress (vibrations, shaking), and the cross-sectional area, fit a strain relief behind
the soldered joint. To function effectively, the strain relief and the soldered joint must be on the same frame
(Figs. 11 and 12). Max. distance between the soldered joint and the relief point is 60 mm in equipment and 40
mm on PCBs. Make a loop in the wire between the soldered joint and the relief point (Figs. 11 and 12) for
cross-sectional areas from 0.14 mm2 to 0.34 mm2, also fit a 5 mm long shrink-on tube over the end of the
insulation (Fig. 12).

Insert pin cable lugs in soldering lugs with holes (similar to Figures 7d and 7e) or place them on soldering lugs
not provided with holes.

For further information on the crimping of pin cable lugs see MS 300.1

1. Soldering of conductor with pin cable 2. Direct soldering of tinned conductor

lug (vibration stresses) (no vibrational stresses)

Fig. 9 Fig. 10

Example : Soldered connection with pin Example soldered connection without

cable lug strain relief (0.14 mm2 – 6 mm2)
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3. Distance of strain relief 40 – 60 mm 4. Shrink on tube

to soldered connection
Fig. 12
Fig. 11
Example : Soldered connection with
Example : Soldered connection with strain relief and shrink on tube
strain relief (0.34 mm2 – 6 mm2)
(0.14 mm2 – 0.34 mm2)

Terminal blocks – Connections

On terminal blocks connect only one conductor to each termination. In exceptional cases (e.g. modifications on
site) terminal blocks can have a second conductor of the same cross-sectional area connected at each
termination. In doing so check that the insulation of each conductor is fed well into the funnel shaped opening of
the terminal.

Bend adjacent soldering lugs alternately forwards or backwards before soldering the individual conductor ends.
When using a link for paralleling isolatable terminal blocks (types 8WA2 340 or 8WA3 34) a conductor cross
sectional area of only 6 mm2 instead of 10 mm2 can be connected.

Whenever possible, use pin cable lugs (crimped terminal posts from Pfisterer for example) for connecting
stranded Al conductors 25 – 185 mm2. Use a rounding tool (for example, Pfisterer, HSMA No. 1k14 214) for
sector –shaped solid conductors. The minimum clearance between live crimped shanks of the pin cable lugs
must be adhered to (see fig. 18). Should it be necessary, however, to reduce this clearance the shaft must be
insulated with an insulating sleeve or shrink-on tube.

Tighten contact screws using torques to VDE 0609 according to terminal size and thread diameter (Figs. 13 and
14).

Terminal block for Single connection of

Mounting rails DIN 46277

32 mm Torque 35 mm Torque Solid Fine- Stranded Soldered Identification
G-bar wires stranded wires m, connection1) of cross-
Cap bar and very sm of solid sectional
e (m) fine wires e area
stranded according to
wires f, US
fst with standards
end (AWG)
sleeves
Order Nm Nm
mm2
No. Order No. mm2 Mm2

mm2
8WA1 16* 0.5 0.4 mm 0.5 - - - 22 – 12
8WA1 17* 0.5 Ø-6 2.5 2) 0.4mm Ø 22 – 12
0.4 mm 0.5 – -1.5

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Ø –6 2.5 2)

8WA2 - - - - 0.4mm Ø – -
150 1.5
8WA2 0.5 0.4mm Ø 0.5 – - 30 – 12
180 –2.5 1.5 0.4mm Ø –
8WA2 0.5 - 1.5 22 – 12
16 0.6mm Ø 0.75 –
8WA2 0.8 -6 2.5 2) - - 18 – 10
24
1.2 1.5 – 10 2.5 – 4 - - 16 – 6
8WA2
40 3.0 1 – 16 - 16 – 50 - 10 – 2

8WA2 1.2 6 – 50 16 – 35 - - 16 – 6
50
10.0 1.5 – 10 4 – 10 50 – - 1/0 – 3/0
8WA2 120
16.0 - - 2/0-300
340 2) 50 – 95
70 - 240 MCM
- 70 – -
8WA2
185
610 2)

8WA2
710
8WA3 1.2 1.5 – 10 1.5 – 10 - - 16 – 6
34 2)
8WA3 1.2 1.5 – 16 4 – 10 - - 17 – 6
40
1.2 1.5 – 16 4 – 10 - - 17 – 6
8WA3
41 3.0 6 – 50 16 – 35 16 – 50 - 10 – 2

8WA3 10.0 - 3.5 – 95 50 – - 1/0 – 3/0

51 120
16.0 - 95 – - 2/0-300
8WA3 185 70 – MCM
61 0.8 0.8mm Ø 240 -
-6 2.5 – 6 18 – 10
8WA3 0.8 0.8mm Ø - 0.4mm Ø
71 -6 0.5 – 4 -1.5 18 – 10
-
8WA3
241

8WA3
251
8WA5 0.5 0 mm Ø 0.5 – - - 20 – 14
160 - 2.5
8WA5 0.8 0.8mm Ø - - 18 – 10
240 -10 1.5 – 6
1.2 - - 18 – 6
8WA5 2.5 – 16 4 – 10
400 3.0 - - 10 – 2
6 –50 10 – 35
8WA5
500
8WA1 201 0.5 0.6mm Ø 0.5 – - - 18 – 12
8WA1 202 -6 2.5
0.1 1 – 10 - - 14 – 8
8WA1 204 1–4
1.2 1.5 – 16 10 – 25 - 14 – 6
8WA1 205 1.5 – 16
0.3 - 10 – 50 - 12 – 2
8WA1 206 4 – 35
10.0 - 16 – 95 - 8–0
8WA1 211 16 – 70

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

8WA1 212 0.5 0.6mm Ø 0.5 – - 0.4mm Ø – 18 – 12

-4 2.5 1.5
8WA1 221 0.8 - 0.4mm Ø – 14 – 8
1 – 10 1–4 1.5
- - 18 - 12
- - 0.4mm Ø –
1.5

* Terminal blocks for 15 mm top-hat rail

1) Crimp fine stranded wire in a pin cable lug and solder the latter

2) Use only 15 mm long end sleeves

Fig. 13

Coordination of the conductor cross-sectional areas in mm2 and in AWG to Siemens terminal blocks and the
torque for terminals screws

Manufacturer Terminal type Screw dia. Screwdriver Screwdriver Torque

blade torque step
mm Nm
Siemens 8WA1 201; 301; 401; M3 0.5 x 3 II 0.5
501; 601
8WA1 202; 302; 502; M3,5 0.6 x 4 III 0.8
602; 721; 722
8WA1 604; 734 M4 0.6 x4 IV 1.2
8WA1 204; 304 M4 0.8 x5 IV 1.2
Phonix UK2.5; MBK M2.6 0.5 x3 I 0.4
UK3; UKK3; MBK3; M3 0.5 X3 II 0.5
UK4; USLKG4
UKN4; UDK4; PIK4;
SSK/N

UK5; SSK5; G5;

SLKK5; UKK5

MBK5; MSLKG5
NLTK4; MK-WW; M3 0.6 X 4 II 0.5
SSK0525-F; MXX5
USLKG10; UKN10; M4 0.6 X 4 IV 1.2
URTK/SS, USLKG 16
UK10; UK16; NLTK10; M4 0.8 X 5 IV 1.2
UKN16; MBK10
Weidmuller SAK2.5; SAKD2.5; M2.5 0.5 X 3 I 0.4
AKZ1.5
EK2.5; NT2.5
SAK4; AKZ4; EK4; M3 0.6 X 4 II 0.5
DK4; R2.5; STV
SAKN6N; EK6; NT6; M3.5 0.8 X 5 III 0.8
SAKT; SAK6 Ex
SAKA10; SAKB10; M4 1.0 X 6 IV 1.2
SAKC10; NT16

Fig. 14

Terminal blocks with screw driver guides – appropriate torque steps for the 4-step electrical screwdriver

Use an electric screwdriver if a large number of cable cores are to be connected to terminal blocks having
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screwdriver guides. The torque of the electric screwdriver can be adjusted in 4 steps to suit the permitted
torque for the terminal block (Fig. 14)

Terminal blocks with plug connection (type 8WA4 01, Fig. 13) are designed for 500 V AC or 600 V DC in
accordance with VDE 0110, Group C. In order to take advantage of the full nominal insulation level of these
terminal blocks placed side by side to form a continuous terminal strip, solder conductors and fit non-insulated
flat connectors to terminations on alternate sides.

Soldering lugs on these terminal blocks which are not connected must be broken off. The remaining blade
contacts can still be used for fitting flat connectors after the soldering lugs have been removed.

If insulated flat connectors are employed the blade contacts can be reserted adjacent to one another (Fig. 16)
Without these steps these terminal blocks with connection can only be used at a nominal insulation level of 125
V AC or 110 V DC.

If mounting rails are used as protective conductor bars for terminal blocks, the protective conductor terminals
can be placed side by side with the insulated main conductor terminals and neutral terminals in any order (Fig.
17). Mounting rails to DIN 46 277 made of steel have the same conductance as the given equivalent copper
cross-section (qcu)

Mounting rail Qfe mm2 Qcu mm2

Top-hat rail 15 mm 8WA6 01 22 2.5
Top-hat rail 35 mm 5STI 141 46 6
G-rail 32 mm 8WA7 44 93 16

Fig. 15 Fig. 16

Staggered soldering of conductors Insertion of non-insulated flat connectors

Fig. 17

Terminal strip consisting of terminal blocks

8WA5 240, neutral isolating terminals 8WA5
250 with feed-in terminal for the 6 x 6 mm
neutral conductor bar and protective
conductor terminals 8WA4 245. The 32 DIN
46 277 assembly rail is used as a protective
conductor bar.

Equipment terminals – Busbar connections

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

1) When using end sleeves the maximum cross-sectional area of the

conductor that can be connected is reduced by one step
Fig. 18

Relationship to the conductor cross-sectional areas in mm2 to the

terminal screw sizes and the types of equipment terminal

The minimum clearance (air clearance) between two live parts (phase-to-phae), when making connections on
electrical equipment with non – insulated cable terminations, connecting lugs (Fig. 24) etc., is defined by the
equipment terminals and connecting lugs and should be adhered to as far as possible. The minimum clearance
must never be less than that given in Fig. 19. If necessary, use cable lugs with insulated shafts.

Reference voltage in volts Minimum air clearance

DC AC
(r.m.s. value) mm
15 12 0.8

36 30 1.0

75 60 1.2

150 125 1.6

300 250 2.5

450 380 3.5

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

600 500 4.5

800 660 6.0

900 750 6.5

1200 1000 9.0

Fig. 19

Minimum air clearance according to VDE 0110, Table 4, Insulation Group C

The same conditions as given above apply to the minimum clearance between the active parts (conductor
connection) and the metal parts included in the protection scheme (non-active parts). When connecting
individual conductor ends check that this minimum clearnace is maintained by the equipment terminal screws.

With factory built assemblies of switchgear and control gear (referred to as FSK in VDE 0660, Part 5) the
minimum clearance (e.g. 6 mm up to 380V, 10 mm up to 1000 V AC or 1200 V DC have already been checked
by the manufacturer in this respect.

Connect only straight wire (Fig. 18) to equipment terminals. Do not make loops.

Exceptions : On explosion and flameproof equipment units and machines a packing piece must be inserted
when connecting a single conductor to a terminal with a U Clamp (VDE Spec. 0192).

PTB, BVS and TUV do not recognize this type of connection. For this reason conductor ends should be
connected up as shown in Fig. 20. Reason conductor ends should be connected up as shown in Fig. 20. The
given types of connection apply to both solid and stranded wires. In this case all conductors may be connected
up without end sleeves. If a conductor with a cross-sectional area of 35 or 50 mm2 has to be connected up, its
end should be split into two equal haves and the connection made like a double connection.

Crimp cable termination which fit under the U clamp may be used.

The connection of solid or stranded wire ends is illustrated in Fig. 1 and 18. For solid wire connection,
position the conductor ends in these terminals such that when the terminal screw is tightened the conductor end
is drawn into the terminal.

Fig. 20

Connections to terminals with U clamps

Types of connection permitted by PTB

(Physikalisch-Technische
Bundesanstalt)

(III B/E-9581U and 88U) as wel as the

largest conductor cross-sectional areas
in mm2 for the appropriate terminals
screws

Flat terminal strips are only permitted in switchboards when terminal blocks cannot be used for space reasons
(Fig. 21).

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

Procelain terminal blocks must not be subsequently installed in switchboards on constructions sites.

Fig. 21

Flat terminal strip

Fig. 22

Connection of solid wire ends to

terminal posts up to size M6

Terminal posts and screws

Solid wire ends should be connected to terminal posts or screws up to size M6 as in Fig. 22 and from size M8 as
in Fig. 23. Ther connection of solid and stranded wire ends should be carried out as shown in Fig. 1.

If the terminal post diameter is greater than that of the hole in the cable lug, make an auxiliary bus (fig. 25).
Connect two cable lugs by one bolt, as shown in Fig. 26 (see also MS 290).

Bus connections

Connections to fixed busbars or auxiliary buses (e.g. protective earth, neutral/protective-earth or neutral bars)
should be made as in Fig. 24 or 28. The largest tapped holes permitted in copper bars are as follows : up to M3
for a bar thickness of 3 mm, up to M4 for a bar thickness of 4 mm, up to M8 for a bar thickness of 10 mm.

Do not cut threads in aluminium bars. Use through bolts instead.

Non-fused bus connections should be laid earth leakage and short circuit proof according to MS 286.

Should channel mounting terminals be used for bus connections (Fig. 27 and 28) care must be taken that
both terminal screws grip the conductor. When the terminal screws are tightened up the body of the channel –
mounting terminal deforms and the claws grip the edges of the bus, thus pressing the connection firmly against
it (fig. 28).

Twist fine-stranded conductors and fit with end sleeves.

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 Fig. 23 Fig. 24

Double connection of solid wires to a Connection of solid wires to a fixed

connector plate with an arched washer busbar, using arched washers (available
(Messrs. Fleckner-Plattenberg). from E MA-Wz)

Fig. 25 Fig. 26

Cable lug connection, using an auxiliary Connection of two cable lugs, using
bus. one bolt

Bar cross-section Conductor cross- Channel mounting

sectional area mm2 terminal Order No.
Mm
30 x 5 1.5 to 16 8HH5630
6 to 35
8HH5730
40 x 5 1.5 to 16 8HH5641
6 to 35
8HH5741
40 x 10 1.5 to 16 8HH5640
6 to 35
8HH5740

Fig. 27

Cross-sectional areas of conductors which can be

connected using channel-mounting terminals

Prepare tapping points on buses by brushing them until bright metal shows and lightly greasing them with
acidless vaseline, e.g. Centoplex DL 24 or Shell Alvania R3. If the customer requires the bus to be painted, only
12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

paint to about 10 mm of the tapping point.

Fig. 28

Connection of solid or strandard wires,

using channel-mounting terminals

1 Conductor

2 Metal terminal post

Fig. 29

Connection of a stranded cable, using a

clamp terminal

Tools

A selection of tools which can be hired from E MA-Wz Erlangen.

Tool HSMA No.

Electrical screwdriver, 220V/50 Hz, with various bits for 1S50 0050
slotted
screws, adjustable torque
1S50

Selection of torque screwdrivers with various bits

1K14 0120

PZ3 crimping tool for core end sleeves, for conductor cross-

Sectional areas from 0.5 to 6 mm2

1K14 0100

PZ2 crimping tool for core end sleeves, for conductor cross-

Sectional areas from 0.5 to 16 mm2

1K14 0101

1K14 0104
Crimping dies for PZ2 crimping tool 0.5 to 1.5 mm2 1K14 0106

1.5 to 4 mm2 1K14 0110

4 to 6 mm2

10 to 16 mm2

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12/30/12 GENERAL GUIDELINES ON LAYING OF IMPULSE PIPE

Fig. 30
Fig. 31
Electrical screwdriver (made by
Siemens or Weidmuller) Selection of torque screwdrivers

Back to C&I Index

www.bhelpswr.co.in/Technical/C&I/Siemens Catalogues/Cable termination.htm 17/17