WIELAND CONNECTORS OVERVIEW
September 02 2024 | Blog Post, Venus Automation
Reliability and efficiency are critical in industrial environments, where correctly powering machines with quality specified connectors and cables enhances operational performance. Wieland offers a range of advanced connectors, including the revos, RST, and PODIS, each designed to meet the rigorous demands of various applications. For example, the Wieland Revos EX is engineered for hazardous environments, providing secure and explosion-proof connections essential for oil, gas, and mining industries. With robust construction and advanced sealing technologies, the Revos EX ensures both safety and durability in extreme conditions.
The Wieland RST connector series is known for its versatility and ease of use, particularly in building installations and industrial automation. Its pluggable design enables quick, error-free connections, reducing installation time and minimizing the risk of incorrect wiring. This system is ideal for applications requiring flexibility and reliable performance under varying conditions. The Wieland Podis decentralised power bus system integrates seamlessly into complex automation systems, offering a modular and expandable solution for power distribution. With its robust design and ease of installation, podis connectors enable efficient power management across large industrial setups, ensuring consistent and reliable energy supply. Together, these Wieland connectors contribute to safer, more efficient industrial operations, enabling businesses to meet stringent safety standards while optimising productivity.
Connectors and their use in Industry
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Key overview of WIELAND CONNECTORS
Purpose and Function
Applications
Electrical connectors offered by Wieland comprise various families for the many power applications and environmental constraints presented by differing industries. The revos family offers products such as the EX and HD, which are protected from explosive environments and heavy duty industries respectively. The revos RST connector provides tight connecting seals, with high mechanical strength and can be installed and rolled out with ease, according to Wieland’s Plug & Play principle. Wieland’s podis connectors are an innovative power bus system; creating an ideal solution for decentralised, flexible, and simple energy distribution – making them exemplary for modular supply of power such as electric vehicle charging (EV). The podis allows for interconnectivity between machines/systems with large dimensions or interlinking. Thus, anywhere that power needs to be reliably connected to machinery and automated systems – regardless of environment – a Wieland connector will continue that power along its path; safeguarding each cable’s end points from even the most demanding and hazardous surroundings.
features
Wieland Revos, Podis, and RST connectors are designed to handle varying electrical demands in industrial applications. The Revos series supports high amperage and voltage, with some models accommodating up to 830V and 200A, making them ideal for heavy-duty power connections. These connectors boast high ingress protection ratings, such as IP65 and IP66, ensuring robust protection against dust and water ingress. The Podis connectors are tailored for decentralised power distribution, operating typically at 690V with an amperage range suitable for power bus systems. They feature IP65/IP68 ratings, ensuring reliability in harsh environments, and are often used in automation systems where flexible, modular power connections are essential. The RST series is versatile, handling up to 250V and 32A, making it suitable for both power and signal applications in building installations and industrial automation. With IP65/IP68 protection, RST connectors offer secure connections in outdoor and wet environments, ensuring performance under demanding conditions.
integration
Wieland connectors can be integrated into automation and industrial setups by connecting machinery, sensors, and control systems with reliable power and signal transmission. Their modular design allows for quick assembly and reconfiguration, supporting the flexible, scalable nature of automated systems. Additionally, their robust ingress protection ensures durability in harsh environments, making them ideal for maintaining consistent performance in dynamic industrial processes.
Understanding the product - Wieland REVOs
DESCRIPTION
The Wieland revos BASIC is a heavy-duty and flexible electrical connector. With options for screw, crimp, spring, or push-in wirte connection technology, the revos BASIC provides a flexible solution for electrical connectivity. Constructed from die-cast aluminium, the revos BASIC is powder-coated and thus meet the toughest of requirements.
SPECIFICATIONS
Connectivity: Screw, crimp, spring, push-in
Rated Current: 16 Amps
Rated Voltage: 690 V
Multipole Rating: From 6 to 48 poles
Contact Surface: Tin, silver, gold
Material: Die-cast, powder-coated aluminium
APPLICATIONS
The Wieland revos BASIC is well suited for many machine building applications. Anywhere that power or control signals need to be reliably connected, the revos BASIC suits these needs.
DESCRIPTION
The Wieland revos EX is an extreme heavy duty connector that is well suited for explosive environments. These connectors satisfy the extremely high requirements, and the revos EX series are heavy-duty components specified for plants in which explosion protection is a must. The revos EX is classified as intrinsically safe – meaning they have limited energy – both thermal and electrical – that can risk ignition. The revos EX connector housings are constructed from die-cast zinc, preventing them from sparking.
SPECIFICATIONS
Connectivity: Screw
Rated Current: 16 Amps
Rated Voltage: 90 V
Multipole Rating: From 6 to 48 poles
Contact Surface: Tin, gold
Safety: IP54 and IP65, with intrinsic safety assessed by BVS
Materials: Die-cast zinc
APPLICATIONS
The Wieland revos EX is extremely valuable in industries that include volatile areas prone that risk explosion. In operations such as mining, chemical, and the oil/gas industry, the revos EX is an intrinsically safe connector that is greatly resistant to explosion.
DESCRIPTION
The Wieland revos HD is a connector that specialises in high-pole connections. They feature a robust housing that offers space from 15 to 64 poles. Per DIN EN 17 5301-801, the revos HD is designed currents up to 16 Amps, and these connectors boast a high contact density. They are especially valuable due to their compact design.
SPECIFICATIONS
Connectivity: Screw, crimp
Rated Current: 16 Amps (DIN EN 17 5301-801)
Rated Voltage: 250 Volts
Multipole Rating: From 15 to 64 poles
Contact Surface: Tin, silver, gold
Pollution Degree: 3
Safety: IP65
APPLICATIONS
The revos HD is specifically designed for high-pole connections, and are highly valued in applications such as escalators, small motors, and injection molding machines. Their compact design (high contact density) enables them to fit more poles in smaller spaces, and thus makes them ideal for machine, control, and switching systems.
DESCRIPTION
For even tighter spaces requiring industrial connectors, the Wieland revos MINI is a great candidate for fulfilling this purpose. With housings available in either metal or plastic, the revos MINI can suit outdoor and indoor connectivity solutions. Despite their smaller size, they are still well designed to accomodate for up to 12 poles, with a protection rating for up to IP65.
SPECIFICATIONS
Connectivity: Screw, crimp
Rated Current: 16 Amps
Rated Voltage: 690 Volts
Multipole Rating: From 3 to 12 poles
Contact Surface: Tin, silver, gold
Safety: IP65
Material: Metal or plastic
APPLICATIONS
The revos MINI is specifically designed for compact spaces; and – thanks to this design – fits into applications for machine, control and switching systems. Their compact design also enables them to be highly functional for systems involving small motors or lighting technology.
DESCRIPTION
If a configurable industrial connector is what the situation calls for, then there is no need to look no further than the Wieland revos FLEX. It features a modular, flexible system, and the connector can be designed entirely to suit specific and unique requirements. Rated for higher voltages and currents than that of the other offered revos connectors, and fitting into the same powder-coated, die-cast aluminium housings of the revos BASIC, the revos FLEX is highly modular and flexible (as the name suggests!).
SPECIFICATIONS
Connectivity: Screw, crimp, spring
Rated Current: 150 Amps
Rated Voltage: 2.8k Volts
Multipole Rating: From 2 to 20 poles
Contact Surface: Tin, silver, gold
Safety: IP65
Material: Die-cast, powder-coated aluminium
APPLICATIONS
The revos FLEX is specifically designed for any specific requirements. These connectors enable the consolidation of cables for power supply, signals, bus, pneumatics, and fibre optics into one connector that saves space. The modularity of the revos FLEX enables a configurable connector that is entirely according to the user’s needs. These connectors prove themselves particularly useful in industries for wind turbines, machine building, measurement and control technology, and the automotive industry.
Understanding the product - Wieland podis
Decentralised energy distribution – what is it and how do users benefit? In traditional distribution of electricity, individual connections run off of a main power box, with each cable running from from the main to the destination of required power. While this makes sense for small-scale power requirements, as power demands increase, time-consuming planning and installation needs to be carried out. Take the charging of electric vehicles (EVs), for example. A centralised installation will require significantly more material and space in the distribution cabinet as more and more spaces for charging are filled.
This is where decentralisation – via Wieland’s podis – comes in. Decentralised installation allows just one supply line to be run for an entire parking deck. Wieland’s podis use one flat cable that acts as the ‘bus’, where individual connectors can be placed anywhere along this cable exactly wherever is needed. This in turn saves space, materials, and is easily retrofitted; unlike more traditional centralised power solutions. The simplicity of the design facilitates a cleaner aesthetic; and maximises error prevention. Less material and labour is required, and no painstaking planning is required due to the impressive modularity of the design.
Wieland podis uses innovative flat cables and plug-in tap-off modules, making it possible to supply charging stations with just one cable harness with a minimal drop in voltage. Cutting and stripping cables are a thing of the past, speeding up installation, conversion, and expansion; all while minimising waste.
DESCRIPTION
Wieland podis CON is a decentralised tray cable system for the flexible distribution of electricity. podis CON works via a bus system, where the flat cable, supplies power to tray cable connectors such as the podis CON 5G6. The connectors use insulation penetration, where the screws seat within the 5 core cables of the wire. This ensures simple replacement, relocation, and addition of modules. podis connectors are rated with an Ingress Protection of IP65, making them well suited to outdoor parking areas, where moisture and dust will always be a factor.
SPECIFICATIONS
- Core insulation: copolymer/thermoplastic
- Flame retardant: DIN 60332-1-2
- Conductor category: class 6 – very flexible
- Core count: 5 wires
- Dimensions: W 43mm x H 7.5mm
- Oil resistance: EN 60811-2-1
- Protection: IP65 – dust, moisture, and UV resistant
- Voltage: 690V AC
- Current: 41A
DESCRIPTION
SPECIFICATIONS
- Core insulation: polyolefin
- Flame retardant: DIN 60332-1-2
- Conductor category: class 5 – flexible
- Core count: 5 wires
- Dimensions: W 48mm x H 11.5mm
- Oil resistance: EN 60811-2-1
- Protection: IP65 – dust, moisture, and UV resistant
- Voltage: 690V AC
- Current: 100A
DESCRIPTION
Differing from the previous two offerings from Wieland podis, the CON 7G4 is a cable and connector family with differing applications. Still within the realm of decentralised power, the CON 7G4 features 7 core wires in each cable. The 7G4 is rated for a lower current, and the additional wires can be used to route control signals, sensor connections, and auxiliary power without separating into multiple cables. They are a space efficient solution for sending power and control signals – all in one cable.
SPECIFICATIONS
- Core insulation: PVC
- Flame retardant: DIN 60332-1-2
- Conductor category: class 5 – flexible
- Core count: 7 wires
- Dimensions: W 35mm x H 6mm
- Oil resistance: EN 60811-2-1
- Protection: IP65 – dust, moisture, and UV resistant
- Voltage: 690V AC
- Current: 32A
Understanding the product - wieland rst
In applications such as gardens, carparks, walk-in freezers/cold storage rooms, electrical connections are subject to harsh and unforgiving environments. Thus, Wieland offer the RST series of connectors, specifically designed with the highest degree of protection. The RST family of connectors use round plugs and connectors – due to round shapes being an optimal profile for high safety and impervious to environmental influences. Traditional cabling often requires time-consuming planning, installation, with the prospect of retrofitting often becoming a behemoth, and confusing task due to lack of clarity and unstructured cable routing. RST series prefabricated connectors reduce error frequency, while saving time and money by eliminating the need for stripping wires and their insulation. The Wieland RST is thus greatly suited for demanding environments such as solar panels, commercial kitchens and industrial settings. RST connectors are so protected that each single contact is offered with an internal seal.
DESCRIPTION
Wieland’s RST MICRO is a miniature connector advertised as the smallest round connector in the world. With provisions for 2 to 5 poles, the RST MICRO is highly functional despite its extremely small stature. Wherever miniaturisation is an issue, the MICRO is sure to act as a great solution for when electrical connections need to get small. RST connections are secured and sealed against pulling – all while maintaining compactness and full functionality.
SPECIFICATIONS
- Rated Voltage: 250/400V
- Rated Current: 8A
- Pole Count: 2-5
- Diameter: 15/20mm
- Protection Rating: IP66 or IP69 with the optional barrier seal.
APPLICATIONS
The RST MICRO is optimised for the interface between voltage/current sorces and LED modules. It is also ideal for dimming or digital multiplexing (DMX). Even network cabling applications do not pose a problem for these small but powerful connectors.
DESCRIPTION
Wieland’s RST MINI is another miniature connector. With provisions for 2 to 5 poles, the RST MINI is protected in accordance to the IEC 61535. It thus provides protection against electric shock, resistance to excessive heating, and uses the TWISTLOCK locking mechanism to save time and ensure safety in connections.
SPECIFICATIONS
- Rated Voltage: 250/400V – Underwriter’s Laboratories UL 300 V
- Rated Current: 16A
- Pole Count: 2-5
- Protection Rating: IP66, IP68, IP69 with the optional barrier seal.
APPLICATIONS
The RST MINI is a complete installation system including connectors, distributors and cable assemblies. RST MINI connectors are well suited to harsh environments in lighting and building automation.
DESCRIPTION
The RST CLASSIC by Wieland is a versatile round connector ideal for demanding electrical installations. Available in 2 to 7 poles, it features a modular design that ensures reliable and secure connections, even in harsh environments. The connectors are factory-assembled and tested, offering protection against moisture and other environmental factors, making them suitable for outdoor and industrial applications. Their quick assembly and flexibility enhance operational efficiency.
SPECIFICATIONS
- Rated Voltage: 250/400V – Underwriter’s Laboratories UL 600 V
- Rated Current: 20A, 25A, 32A
- Pole Count: 2-7
- Protection Rating: IP66, IP68, IP69 with the optional barrier seal.
APPLICATIONS
The Wieland RST CLASSIC is a durable installation system designed for demanding environments, offering connectors, distributors, and cable assemblies ideal for outdoor and industrial applications. It excels in building automation and industrial lighting, providing reliable, fast connections with high resistance to environmental challenges like water and dust.
