Efficient terminal strip construction and mounting

Control cabinet builders face challenges in cost-effectiveness due to rising costs and a shortage of skilled workers. This article covers the production and mounting process of a terminal strip, from digital construction to marking and mounting, highlighting efficiency solutions for each step.

Despite increased automation in control cabinet building, mounting tasks are mainly manual. Automation is mostly used for material and work preparation, such as preparing the mounting panel and housing, cutting cable ducts and DIN rails, and preassembling wires. Manual tasks include picking components, mounting, wiring, and testing, usually done on the installed mounting panel by a qualified specialist.

To solve these problems, mounting processes must be thoroughly analyzed. The first step is shifting from direct mounting in the control cabinet to upstream module mounting.

Software-supported DIN rail assembly with worker assistance systems

In upstream module mounting, the DIN rail is fully assembled before installation in the control cabinet. Digital preparation of diagrams and optimized workstations with worker assistance systems enhance efficiency.

Data consistency from engineering to production underpins these systems. For instance, most ECAD systems can export data to engineering software like clipx Engineer from Phoenix Contact. Consequently, this software centralizes all components, functions, and marking information, ensuring a seamless digital workflow and eliminating paper-based media discontinuities. Furthermore, the worker assistance software provides only the necessary information for each production step, avoiding extensive documentation searches.

Efficiency can be further increased by using a workstation with an interactive worker assistance system and a pick-by-light system. Controlled by the software, it displays the correct shelf section for each mounting step, guiding the employee through the process. This reduces search times and errors, significantly boosting efficiency, and allows semi-skilled workers to perform mounting tasks.

Marking requirements

After assembling the DIN rail, it is marked for clear, permanent identification, enhancing safety and workflow efficiency. Uniform marking of components can save up to 30% of production time. Phoenix Contact offers a comprehensive range of marking solutions, including versatile materials and intuitive systems, supporting various technologies like thermal transfer, UV inkjet, and laser marking.

Simplifying the identification process with the aid of worker assistance systems

The construction and identification of a DIN rail involve various components and project variations. The worker assistance system simplifies selecting, creating, and mounting markings by using information from the engineering software, preventing errors. Employees use marking software to choose the right marking systems and materials, which are then printed. The system guides users step-by-step in applying the markings, reducing errors and enabling semi-skilled workers to handle complex projects.

Efficient mounting of terminal strips

After constructing and marking the terminal strip, it is mounted in the control cabinet. The challenge is that the elongated holes of the DIN rail are often inaccessible due to mounted components, making it difficult to secure the rail. This has led many builders to prefer the classic method of attaching the DIN rail first and then adding components.

Current methods to mount terminal strips include:

• Leaving spaces for fixing points, which reduces the rail’s capacity.
• Removing and remounting components around fixing points, which is time-consuming and poses a quality risk if components are not correctly repositioned.

Railfix adapters from Phoenix Contact simplify mounting fully assembled terminal strips without front access to elongated holes. The adapters are pre-mounted on the panel, and the DIN rail is placed into the locking clips with guide elements. Using a screwdriver, the rail is levered under the clips and secured with an M5 screw.

The mounting distances of Railfix adapters depend on the DIN rail pitch and the load from mounted components. The zinc die-cast adapters are electrically conductive, allowing shield currents to discharge to the mounting panel.

Read more control cabinet building.

Uncooled DC charging cables for realizing a wide range of charging solutions

With reliable DC charging infrastructure, charging electric cars on medium and long-distance journeys at semi-public and public stations is now practical for everyday use. Long charging times are a thing of the past.

Even with uncooled DC charging cables, charging currents up to 375 A and short charging times are achievable. Power transmission requirements vary by location and application, so optimizing the charging infrastructure makes sense for many operators. The robust Charx connect DC charging cables offer future-proof features and power versions from 150 A to 375 A.

The right power in the right place

Charging infrastructure should match application-specific criteria. For example, a DC home charger isn’t suitable for a highway parking lot, nor is an HPC quick charging station for a residential area. The key factor is the average time a vehicle spends at the location: HPCs are ideal for short stops at highway rest areas, charging parks, and interstates. Medium power stations (50-100 kW) are best for 30-minute to 2-hour stops, such as at shopping centers and supermarkets. Lower power DC charging is suitable for longer stays, like at tourist destinations, amusement parks, and sports stadiums.

DC charging is ideal for tourist destinations like amusement parks and sports stadiums. It also suits private and professional applications, especially with easy DC voltage access (e.g., large photovoltaic systems). Differentiating DC from AC charging requires careful consideration. Phoenix Contact’s charging cables support various DC applications, enabling cost-effective infrastructure. The new CHARX connect standard CCS connectors cover 150-250 kW. CHARX connect professional, with a 4 x 50 mm² conductor, operates HPC stations at 375 A without cooling up to 40°C and higher currents in Boost Mode.

Safe and robust in outdoor applications

The clever sealing concept of the CHARX connect standard DC charging cables ensures complete longitudinal water tightness. Protecting the live parts inside the housing against moisture. This maximizes electrical safety for the user while increasing the failsafe performance of the charging infrastructure.

The innovative two-chamber sealing system marks the next stage in the development of the DC charging cable sealing systems from Phoenix Contact: by physically separating the DC+ and DC- power contacts, short circuits can be completely ruled out.

High-quality materials also ensure the necessary robustness and long service life of the charging connectors – even in constant outdoor use under harsh conditions.

Prepared for four-conductor measurement technology

For reliable billing compliant with calibration laws, DC charging cables and connectors are prepared for four-conductor measurement technology, making them future-proof. This technology records power dissipation in the cable to precisely determine the energy transferred to the electric vehicle.

Sustainable, easy, and cost-effective: repair kits

Despite their robust materials, charging connectors at semi-public or public stations require regular maintenance due to improper handling. Damage often occurs on the mating face. Repair kits allow quick and easy replacement of mating face frames and power contacts, making Charx connect DC charging cables easy to maintain, saving time and costs, and increasing infrastructure availability.

This eliminates the need for costly and time-consuming complete cable replacements. This maintenance is more economical and sustainable.

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Single Pair Ethernet (SPE) enhances modern communication infrastructures. Phoenix Contact offers a comprehensive SPE product portfolio, providing technical solutions and cross-industry expertise.

Unlike conventional Ethernet, Single Pair Ethernet (SPE) uses just one wire pair to transmit data and power. It supports transmission rates from 10 Mbps over 1,000 m to 1 Gbps over 40 m, making it ideal for demanding applications like networked sensors and camera systems. SPE overcomes previous limitations in data rates, ranges, and seamless communication.

Connections of up to 1000 m

Conventional Ethernet is limited to 100 meters for point-to-point connections, requiring additional repeaters or switches for longer distances, which are prone to faults and maintenance. Single Pair Ethernet (SPE) connects devices up to 1,000 meters at 10 Mbps with one cable and supports Power over Data Line (PoDL) technology. SPE can replace specific fieldbus technologies and supports complex network topologies with speeds from 10 Mbps to 1 Gbps. New SPE standards being discussed could enable data rates of ≥10 Gbps for short distances (<15 m) and 100 Mbps for up to 500 m, opening new application fields.

Seamless and secure data communication

Classic industrial systems used Ethernet and many fieldbus systems. The Industrial Internet of Things (IIoT) is making these topologies obsolete, requiring more efficient communication systems. This shift is seen in all applications needing seamless sensor and network communication, where secure data connections are critical.

Cost-efficient factory automation

Factories generate about one terabyte of data daily, and this is increasing. Continuous communication is essential for effective data evaluation. Single Pair Ethernet (SPE) ensures consistent networking from sensors to the cloud. With more sensors and intelligent devices in industrial applications, SPE is the ideal cabling solution—simple, secure, compact, and cost-effective. SPE will be cheaper than current bus and Ethernet component combinations.

SPE and robots: Space-saving and high-performance

Single Pair Ethernet (SPE) benefits autonomous and collaborative robots with higher data transmission rates than conventional fieldbus systems, enabling better communication. It simplifies cabling by combining data and power in one line. Future hybrid SPE solutions will include data and power contacts in one connector. Fewer cables and connections mean fewer errors, faster troubleshooting, and easier maintenance. The smaller bending radius of SPE also optimizes robot handling system design.

Process automation with SPE

In process automation, such as in the oil and gas sector, large sites require complete status overviews and remote control with consistent data flow from sensors to the cloud or ERP systems. Single Pair Ethernet (SPE) provides efficient network structures without intermediary devices. Power over Data Line (PoDL) with SPE enables simultaneous data and power transmission.

Process automation with SPE

In process automation, such as in the oil and gas sector, large sites with massive buildings or tanks are common. Companies need a complete status overview and remote control of all locations with consistent data flow from sensors to the cloud or ERP systems. SPE enables efficient network structures without intermediary devices for signal modulation or gateways. PoDL combined with SPE allows simultaneous data and power transmission in these applications.

APL technology for explosion-protected areas

The Advanced Physical Layer (APL) standard meets high data and power transmission
requirements in explosion-protected areas (zones 0, 1, and 2), used in the
process industry. It combines the 10BASE-T1L standard with the 2-WISE standard
for explosion protection and intrinsic safety. APL covers large distances (up
to 1000 m trunks, 200 m spurs) and ensures interoperability between devices
from different manufacturers. It supports predictive maintenance and modernizes
existing systems cost-effectively using existing cabling and Ethernet protocols
like EtherNet/IP™, HART-IP, OPC UA, and PROFINET. APL benefits industries such
as oil, gas, and chemicals by enabling secure, efficient, and future-proof
networks.

Range advantages for the energy sector

Single Pair Ethernet (SPE) benefits renewable energy management, which requires intelligent data handling due to fluctuations. For wind turbines and photovoltaic systems, energy must be measured and fed into the grid intelligently. Modern wind turbines exceed 100 m in height, making conventional Ethernet insufficient. Operators use fiberglass or wireless solutions, but SPE’s increased range is advantageous for covering these distances in wind turbines, solar parks, and power-to-grid/gas systems.

SPE via connector or terminal block

SPE’s performance benefits devices with smarter, more compact, and complex functions in building technology and industrial applications. Device manufacturers need to consider connection technology, often requiring IP protection. Options include IP-protected connectors or cable glands. PCB terminal blocks suitable for SPE can be used inside devices, offering placement flexibility and ease of installation with familiar screw and Push-in connections. Clear color coding of SPE cables helps avoid installation errors, even in challenging environments.

Space-saving connection technology

SPE PCB terminal blocks excel in IP20 environments, like building technology, where space constraints limit connector use. They are ideal for distributor boxes and flush-mounted sockets, offering a space-saving alternative. These terminal blocks allow flush-mount and DIN rail devices to connect directly via an SPE installation cable and integrate into the network.

Discover more about SPE technology

Surge protection for up to 1.5 Gbps

As telecommunications connections speed up and the active technology (e.g., router) is now moving into meter cabinets, protecting these devices from surge voltage is crucial for stable operation even during thunderstorms. The surge protection should be easy to install and not impair transmission.

No fear during a storm

Modern telecommunications devices are essential at home and in the office. Ensuring their unrestricted operation is now an absolute necessity. Using appropriate surge protection prevents unexpected failures due to voltage peaks. Besides power supply protection, VDE 0100-443 standard and TAR VDE-AR-N 4100 recommend protecting the communications interface. With many telecommunications systems available, which protective device is suitable?

DSL interfaces and their transmission speeds

DSL interfaces provide Internet speeds from 16 Mbps (ADSL2) to 300 Mbps (super-vectoring VDSL/SVVDSL). Vectoring VDSL reduces crosstalk interference in copper telephone cables. Transmission frequencies range from 2.2 MHz (ADSL) to 35 MHz (SVVDSL), important for selecting protective devices with matching cut-off frequencies. Manufacturers should specify both cut-off frequency and maximum DSL speed. G.fast offers speeds up to 2 Gbps over very short copper lines (<100 m).

Suitable protective devices

To prevent signal from being influenced, attenuation at high frequencies must be negligible. High-speed data transmission, especially with super-vectoring, requires symmetry of the copper wires against ground. The DT-TELE-WM-RJ45-PT-I product ensures minimal impact on transmission quality, even at 300 Mbps (VDSL) and 2 Gbps with G.fast. Deutsche Telekom tests confirmed its excellent transmission behavior and compatibility with VDSL, VVDSL, SVVDSL, and G.fast.

Quick and easy installation

The DT-TELE-WM-RJ45-PT-I can be easily snapped onto a DIN rail or mounted on a flat surface or perforated board using pull-out tabs. Its electrical connection is flexible and user-friendly due to the combinaton of Push-in technology for installation cables and RJ45 jacks for assembled telephone cables.

Protection against incorrect installations and power-cross

If a cable with too high a voltage is connected to the connection terminal blocks, the integrated current sensors limit the current and voltage to safe levels. Once the error is rectified, the sensors return to normal. Even in extreme cases, like a power-cross or a 230 V AC line connection, the DT-TELE-WM-RJ45-PT-I protects the end device (e.g., router) and remains in a safe state.

In case of thermal overload, an internal disconnect device disconnects the affected protective element from the data line. A red status indicator signals that the DT-TELE-WM-RJ45-PT-I needs replacement as its protective function is compromised. This surge protection limits high pulse voltages and harmful energy from miswiring, preventing damage to the TC device.

Required performance

The IEC 61643-22 standard provides information on the required performance of protective devices, specifying surge voltage categories (D1, C2, C1) based on installation location. Standardized testing verifies these properties. Well-documented devices provide data for various standard pulses, reflecting installation location. For example, devices at the building entrance (first lightning protection zone) should meet category D1 requirements, while subsequent levels should meet C2 and C1. The described protective device meets all these categories and can be used in any lightning protection zone.

Read more about The new DT-TELE-WM-RJ45-PT-I surge protective device.