1 [carol elmex TERMINAL BLOCK TECHNOLOGY Basic Construction: elmex Terminal Blocks are mounted on 35, 32 or 15 mm Standord Rois types: TH35, G32, THIS (IEC6O715), or 1535, 1832, TS15 (DIN EN Standard). The terminal blocks hove ‘© modular design, so thot they can be installed side by side, simply by clipping-on, to form a uniform ‘assembly on mounting roils. This feoture yields simplicity, economy cand compociness in instollation, ond allows for dé extensions ‘Atypical Feed-though terminal block consists of 1.0 Insulated Housing : Stondard Designs with 1.1 Polyamide 6.6 12 Melamine 2.0 Conductor Clamping : Standard Designs with 2.1 Screw Clamps - Stel 2.2. Screw Clamps - Spring Loaded 2.3 Screw Clamps - Copper-Alloy 24 Spring Clamps 2.5, Stud-and-nut clamping for cable Lugs 3.0 Current Bar : Current carrying part of Terminal Block. 4.0 Mounting Springs: For mounting on 32mm rail (TS 32/632), in case of Melamine Housings. celmex terminal blocks con accept sold ond stranded conductors as well a flexible conductors of size upto rated connection capacity, 0s specified inthe detiled specifeation sections ofthis catologue. ‘The obove basic construction is developed further into various individual ‘ypes of Terminal Blocks for diferent opplicatons, such as Mutlevel 'ypes, Eorth Terminals, Distribution Block, Fuse Feed Through fypes, Component Housing types etc Panel Mounting type, Wire Wrap type, Termipoint type ele., have different designs for connection of conductors and ore described under respective sections ofthis caiclogue. 1.0 Insulated Housings : Two types of insulated housings are employed in elmex terminal blocks 1. Thermoplastic : Polyamide 6.8, Injection Moulded 2. Thermoseting : Melamine, Compression Moulded Polyamide 6.6 (or Nylon 6.6) is resin belonging tothe Nylon family cof thermoplastic moulding materials. Polyamide 6.6 possesses a good bolance of various properties tensile cand flexural strengths, allowable service temperature, impoct resistance, abrasion resistance, resistance fo fuels, lbriconis and many chemicols (except sirong ocids and oxidising agents). It has good electrical properties, for low voltage opplictions. It is resistont to surface discharge with CTI > 600 (IEC-601 12). Melamine iso resin belonging to the group of Thermosetting compounds, generally known as ominoplasts. it has on excellent resistance to deformation, particular hardness and « very good surface brilonce. ‘Melamine has on optimum dimensional stbiliy ond a strong resistance to surface discharge with CTI > 600 (IEC-60112). It does not ignite and gets converted into chor form in case of fre. Its abrosion ond chemical resistant, waterproof and resists high ond low temperatures within the limits of 40 °C and 130°C. ‘Melamine is portcularly suited for use in severe environmental conditions and is preferred for Circuit Breaker Panels, Refineries, Chemical Plants, potentially explosive installations and any other high risk environments in general 2.0 Conductor Clamping 2.1. Screw Clamp (Steel) 2.1.1 Contact Clamp : ‘elmex Screw Clomp consists of a U-Shoped steel par, called Contoct CClomp and a washer base or cheese head screw. The vertical arms of the Contact Clamp are folded ot the top end into lips, overlpping each other. The lip from each arm locks ino recess provided on the other arm. This double locking is on fuisianding feoture of elmex Screw Clamp desiga, which allows tightening torques in exces ofthe values specified by the Stondords, In addition, in the event of inadvertent over tightening, tis design prevents domoge tothe threads tnd deformation of Contact Clamp. cr =f j= ‘The bottom face ofthe 'U' hos serrations, which grips the conductor Fmly uring tightening. The lips oe driled ond threaded cooly in specil machine fo produce rolled threads for higher mechonical strength of ‘threads which can tke higher fghtering foroue ‘The Contac Clamp undergoes Het Treotment for increesed hardness and sirengih. tis then zinc plated ond passivoted to a higher degree of plating ‘thickness thon suolly adopted. elmex Screw Clamps therefore have very good resistance fo normal aimospheric corrosion, ‘Heat Treatment: elmex conioc clamps are subjected foo specol heat ‘treatment process ensuring uniformly of temperature over the ene camp surface and consistent resus of hea! treatment so thatthe inner threads of the clamp achieve a uiform ond strong weor resistanceQe 2.1.2 Clamping Screws : elmex Screw-Clomp uses cold-orged rolled threaded washer-bose or cheese-heod screws (or Philips-heod screws in specific cases). The screws ore hardened and tempered for increased strength and wear-rsistance. After frst assembly they become captive in the heusing due to washer base feoture (for melamine housing) ond « circular ring provided in the housing for cheese head screws. These Screws ore corrsion-proeded by zine plaiing ond passivated to a higher degree of plting thickness, under contrlled plating process. The screws have a flat bottom which creates a bolanced pressure on current bar for conductorclomping 2.2 Screw Clamp - Spring Looded For high-vibration applications telmex offers spring looded Screw Clamp Terminal Blocks. Ahough elmex standard screw- clamp design is croady resistant fo vibrations, further strengthened ogoinst vibrations by provision of compression springs in the terminal block The springs are assembled under the contact clamp in pre-stressed condition. When the screws are fuly tightened upto specified torque, the springs under the contact clamps provide additional pressure between current bar and conductor, which makes the spring loaded terminals especially suitable for high vibration applications. The compression springs are made of siandard spring-stel. All other ports are same as fr the Serew-Clamp design. 2.3 Screw Clamp (copper-clloy) In the elmex design of copper- alloy terminal blocks, the Stee! Screw-Clomp is replaced by copper-olloy _screw-clamp. Protection against atmospheric corrosion of copper-alloy is achieved by fin plating, to a higher degree of plating thickness, in a controlled plating process. The tin ploting has under-coot of rickel Plating to prevent zinc migration, By appropriate selection of materials and processes, the phenomena of stress corrosion cracking is taken core of in elmex copper-olloy screw= clamp. ‘The clamping port in elmex screw clamp is of special design, such thot 1s the conductor damping is achieved by tightening of screw, the top- portion bends elastically, so that screw threads are gripped to prevent loosening 2.4 Spring Clamps: telmex spring clamp consists of specially shaped stainless steel comp, which functions as a spring for developing necessary contact pressure MP cory | between Current Bor ond conductor. Current Bor is the current carrying port in the terminal block, and it is provided with serrations to grip the conductor. ‘The spring clamp is brought under tension by inserting 0 screwdriver This creates necessary opening in the damp for inserting conductor. ‘tare conduc sly inset hn scowdeverewihdeve The cdomp arm thereby presses the conducior firmly against curent bar, by spring adion of the clamp. 2.5 Stud-and-Nut Clamping for Cable-Lugs This conducor damping design is especialy developed for recivig Rng-ype cr Forkype cable ug. The leingl block consis of Housing, Suds ond Nuts nd the Curent Bor. The Ring type lugs con be inserted in Studs, while Fork ype lugs reinserted under Nuts The lugged cables ore camped to the curent bar by fightening the nus, Standard spanner can be used in case of "Nut Die” ype of Stud Terminals Fox Scewdve opraed sid termina the suds provided with special org- rut with ast atthe tp for screwdriver. This ype is especialy developed where spoce-imiaions may not allow he use of spanner for damping cables. ‘Allthe metal prs in these ypes of erninals cre made of Copper alloy ond fin ote with Nickel under coa for protecion aginst cmspherc corrosion. 3.0 Current Bor ‘elmex Current Bars ore mode of clecrofic copper or «igh quay copper clloy ond fin plated with higher than usuol plating thickness, o meintin the ‘onl surface free from cimospherc corosion. Nickel undercoat prevents ne migration in case of copper alo curent bors. Special features of elmex curent boris the provision of longitudinal serrations {to gip the conducor while fahlening, ond ct int thin cxde fim of conductor. ‘The contoct estonce remains ver low, once the conduc mil amped. 4.0 Mounting Spring : ‘The Spring used in Melamine Terminal Blocks for fixing ra | thom on the Rail is made of high grode Stainless Stoel fo tetoin the spring tension over a longer period. The design ‘of the Terminal housing incorporates notch so os fo provide a sel-locking mechenism to prevent the spring from slipping ‘ut of he housing,