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How to Level-Up Wiring Installations

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2021/07/07

How to Level-Up Wiring Installations
Wiring terminations are faster and consume less space when made using multi-level terminal blocks.
Terminal blocks are the fundamental product used to interface wires and cables to internal components for any type of electronic or electrical equipment. Designers need reliable and easy-to-use products arranged to make the best use of the limited space available. Classic screw-type single-level terminal blocks are the typical method, but these are relatively inefficient. Responding to customer needs, Dinkle has developed higher-performing, multi-level, spring-type options to provide the best performance in small spaces, especially for multi-conductor cable applications (Figure 1).
Dinkle offers a portfolio of terminal blocks and accessories, including multi-level designs, to help designers cost effectively save space, simplify installation, and make troubleshooting more convenient.
Figure 1: Dinkle offers a portfolio of terminal blocks and accessories, including multi-level designs, to help designers cost effectively save space, simplify installation, and make troubleshooting more convenient.

Beyond Basic Connectivity
Basic 'feed through' terminal blocks have one wire connection point on each side, with a conductive bar between them. This electrical portion resides inside an insulated housing. Some terminal blocks mount directly to back panels, while other styles install on DIN rails or may be stacked side-by-side to save space. Designers must select terminal blocks with the right voltage, ampacity and physical sizes to match the application.
 
Standard terminal blocks can be bulky and consume valuable panel space. The classic screw-type connections often have screws and washers that can be lost, or they may require ring or fork lugs to be crimped on to wire ends. Screwing down each terminal connection point requires tools and takes a tremendous amount of time. Once assembled, the screws must be correctly torqued to ensure a proper connection. Too loose will cause the wire to overheat or disconnect, while too tight can result in a stripped screw or snapped screw head. Some designs use a spring cage-type connection, which is a screwless design that can accept a bare wire, or a wire with a pin ferrule crimped on to the end. However, this style still requires a tool for both wire insertion and wire release, which is still not optimal, taking up time and requiring the proper tools to accomplish.
 
Dinkle offers DKN Series screw-type terminal blocks and AK Series spring cage type terminal blocks, because some users and industries have specific technical, commercial, or historical reasons for continuing to use these traditional products. However, each of the potential issues with screw-type and spring cage type terminal blocks can be overcome by using newer DP Series multi-level push-in design (PID) terminal blocks offered by Dinkle (Figure 2).
Dinkle’'s DP family of terminal blocks incorporates push-in spring-type connectors with single-, two- and three-layer form factors in a variety of sizes.
Figure 2: Dinkle's DP family of terminal blocks incorporates push-in spring-type connectors with single-, two- and three-layer form factors in a variety of sizes.

More Connections, Less Space
Many power and control circuits, ranging from 24VDC up to 240VAC, consist of two-wire circuits. Signaling applications are often two-wire or three-wire circuits. To address these use cases, a natural choice is to incorporate multiple levels within a terminal block so that all conductors of a two- or three-conductor cable can be terminated in one clearly identified area (Figure 3). Furthermore, many signal cables also have a shield conductor, so Dinkle also offers the DP2.5-3L-L3PE, a multi-level terminal block which includes an additional connection point to ground the shield to potential-earth via the DIN rail.
Multi-level PID terminal blocks, like the Dinkle DP family of products, provide a compact and reliable way to make industrial-grade wiring connections.
Figure 3: Multi-level PID terminal blocks, like the Dinkle DP family of products, provide a compact and reliable way to make industrial-grade wiring connections.
Some users are concerned that multi-level terminal blocks can be harder to work with because of the density. However, Dinkle has developed multi-level terminal blocks with users in mind, so the physical dimensions and marking provisions make them easy to use. For example, the DP2.5-3L is a typical three-level terminal block accepting 2.5mm2 size wires, where the overall width may be only 5.1mm, yet six conductors can be terminated, saving 66% of the valuable control panel space as compared with using multiple DP2.5 single-level terminal blocks. Even the DPP2.5, a two-level terminal block, can save up to 50% of valuable space compared to the single level terminal blocks. Multi-level terminal blocks speed up installation and make it easier for personnel to troubleshoot any issues because all of the related terminations are close together.

Reliable Terminations
Another Dinkle development of the DP Series is the spring-loaded PID connection, which entirely does away with screws and washers. Some early spring-cage designs required push-down tools for wire insertion. However, the newest generation of PID terminal blocks by Dinkle accept direct insertion of solid wires or ferrules, or a simple tool to insert bare stranded wires. This same tool is used to release any wire.
 
PID terminal blocks can be wired more quickly than screw-type components, reducing wiring labor by at least 50%. Another key benefit is constant spring pressure, which resists vibration better than screw-type terminals, making PID terminal blocks the best choice for many types of equipment.

More Options and Benefits
Dinkle has also worked to create a range of terminal block options to increase efficiency and performance for a variety of user applications:
  • Plug-in bridge: Can be easily inserted to cross-connect multiple terminal blocks at once.
  • Marking labels: For clear identification of each conductor on a multi-level terminal block.
  • Partition/end plates: Used to isolate and group terminal blocks from each other.
  • Test Plugs: For quick electrical testing for each terminal.
  • Fuses or disconnects: So additional components are not required.
To meet user needs, Dinkle offers a complete range of terminal blocks rated up to 600V and 82A, carrying UL approvals, and accepting wires sizes anywhere from 20AWG up to 4AWG. Dinkle uses high-quality materials like PA66 plastic and red copper (with a 99.99% copper content) to ensure best conductivity, lowest temperature rise and flame-retardant performance across a range of temperatures from -40°C up to 120°C. Dinkle rigorously tests their products in accordance with UL 1059 and IEC 60947-7, and even goes beyond industry standards to include oven and salt spray testing to ensure all aspects of the terminal block remain viable and resist any cracking, deformation, melting or corrosion (Figure 4).
Dinkle performs extensive tests, even going beyond industry standards, to ensure the best terminal block quality and performance in all specified operating conditions.
Figure 4: Dinkle performs extensive tests, even going beyond industry standards, to ensure the best terminal block quality and performance in all specified operating conditions.

Top Terminal Block Performance
Although terminal blocks are a basic component, there have been many improvements over screw-type terminal blocks in recent years. Dinkle offers a complete range of PID terminal blocks and accessories, so users can design compact and cost-effective solutions that speed up installation and improve the serviceability of their equipment.