The inserts consist of plastic to insulate the individual contacts. The properties of an insert are defined by its electric parameters.

Inserts are characterized by their contact resistance and by structural properties such as size, number and spacing of the contacts. For example, feed-through connectors which combine the terminal and the plug-in connector, or modular plug-in connectors which accommodate several inserts of various connection types with a single housing. The service life of any connector depends on its mechanical properties, which include the number of plugging or mating cycles, together with it’s resistance to vibration and impact.

Fixed pole standard inserts
(up to 216 poles, rated current up to 100 A, rated voltage up to 1000 V)
Connection systems:

• screw connection
• tension spring connection
• axial screw connection
• crimp connection

Fixed pole MixMate insert
Power and signal contacts are integrated in one plug-in connector

Feed-through connector CabinetMate
Specially for connecting directly to the switch cabinet
(up to 64 poles, rated current up to 16 A, rated voltage from 500V)

Modular inserts ConCept system
(free choice of assembly, up to 280 poles, rated current up to 40 A, rated voltage from 630 V).

The housings protect the inserts – and thus the electrical connection – from external influences. The degree of protection is defined by EN 60529: the standard stipulates various protection classes. Surface treatment determines the corrosion protection of the housing. Weidmuller housings are usually cast from aluminum alloys, whilst Plastic housings can also be used, in less extreme ambient conditions.

Connector housings are available in two heights. The lower form is used when there is only restricted height for the connector. The “high” form can accommodate a larger quantity of conductors.





The lower section of the housing can be fixed to the machine or switch cabinet (base and
mounted housing) or can simply connect to the cable like the upper section for flexible use (coupling housing).

The base housing is closed at the bottom and serves to mount the housing on the machine frame.


The mounted housing is open at the bottom so that the cable can be inserted directly into the switch cabinet. Here an additional seal is necessary between housing and switch cabinet wall, in addition to the seal between the upper and lower section of the housing.





The coupling housing is also closed at the bottom. It is used in applications where two cables are to be connected without having to mount part of the plug-in connector to the switch cabinet or to the machine.

Fastening systems
Weidmüller supplies HDC housings with four different fastening systems:

• transverse locking clamp (on upper or lower part)
• longitudinal locking clamp
• central lock
• screw closure (RockStar)

Material
Weidmüller housings are usually made of metal (size 2 to 12). For size 1 the user has a choice between metal and plastic. All metal housings have an impact-resistant, powder-coated surface. Thermoplastic housings are heat-proof and can also be used for high temperatures.

The black RockClassic Stainless housings, with its specially hardened surface, is recommended for highly aggressive ambient conditions and extreme climatic conditions. All metal parts of the black RockClassic Stainless housings are made of stainless steel for optimum corrosion protection.

Class of protection
The RockClassic housings correspond to protection IP 65; they are dust- and water-proof. In addition, Weidmüller also offers the RockStar series with a choice of IP 68 and EMC housings. RockStar housings are shock and vibration tested to EN 61373 cat. 2 and withstand the highest mechanical loads.

There are four common types of connection: screw connection, tension spring connection, axial screw connection and crimping. The contacts for screw, axial screw and tension spring connections are already mounted, for crimp connections the customer chooses the corresponding contact.

Contacts
The contacts are the core of a plug-in connector. They constitute the actual connection between two conductors. Here two kinds of contact are necessary: plugs and sockets. The plug conducts the electrical connection on its outer surface. It is introduced into the socket, which conducts the electrical connection on its inside surface. Heavy Duty Connectors have copper alloy contacts. The contact surfaces are plated with gold, silver or tin-lead: silver improves conductivity, gold is corrosion-proof.

Crimp contacts are available in punched/rolled or twisted, solid form.

Punched/rolled contacts:

Weidmüller CS/CB contacts are made up of two metals. An upper spring of steel produces excellent mechanical properties. Weidmüller connectors can also uses gold or tin/lead for optimum conductivity. The two materials with their differing properties constitute a contact.

Turned, solid contacts:

The turned contacts are based on copper alloy, with gold or silver contact surfaces.

Fiber optic contacts:

Weidmüller also offers fibre optic contacts.