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What’s the quickest way to terminate a conductor to a heavy-duty connector (HDC) insert?

There are many reliable ways of connecting a wire to the pin or socket of HDC connectors. With everyone looking to save time (and money) in their production facilities there is a new contender on the block.

Heavy-duty connectors are permanent fixtures within machinery and plant engineering, as well as in the railway and wind power industries. They also support the trend towards modularisation. Type and application-dependent inserts are available with various connection systems for screw, tension clamp, PUSH IN, crimp or axial screw connection. These are now also joined by inserts fitted with the new, future-proof SNAP IN connection system.

The RockStar® SNAP IN quick termination system is a revolutionary connection method bringing zero force conductor insertion to a whole new level. Stranded wires of 0.5 to 2.5 mm2 (AWG 20 to 16) without crimped-on wire-end ferrules can be easily inserted into the open connection point. “Click” and that's all it takes to create a secure connection. No tools are required. The connection can withstand harsh environmental conditions with heavy shaking and vibrations. The connection point can be opened by activating a pusher with a screwdriver, to remove the connected wire. The innovative connection system is being used for the first time in the HDC-HE inserts in the RockStar® series. Fixed-pole inserts with 6,10,16 and 24 ways are available (size 3, 4, 6 and 8), with a rated voltage of 500 V/16 A. The new inserts allow for quicker, easier, more reliable and more flexible wiring. Maintenance work is significantly quicker.

Users can easily insert the stripped, stranded wire into the connection point for the first time, with no need to crimp on a wire-end ferrule which significantly reduces material and processing costs while also speeding up the connection process. The SNAP IN connection system is designed to close automatically as soon as the stripped wire has reached the correct position and the spring has triggered. The operating principle is comparable to that of a mousetrap. The contact closes with a noticeable “click”, and holds the wire in place, protected against vibrations providing a high level of reliability even under the harshest environmental conditions,

And of course, it is still possible to use stranded wires with wire-end ferrules and plastic collars with cross-sections ranging from 0.5 mm2 to 2.5 mm2

Every connection is also provided with a “test point”, meaning that testing procedures can be carried out with a standard 2.0 mm test plug.

The rated voltage is 500 V in accordance with DIN EN 61984, and 600 V AC/DC in accordance with UL/CSA. The rated current (DIN EN 61984) is 16 amps.

The insert material consists of a PC glass-fibre reinforced insulating material PA 66/6. The plastic is UL-listed and approved for use on railway constructions. The flammability rating in accordance with UL 94 is V-0. The inserts have a temperature rating ranging from -40 °C to 125 °C. They are plug-compatible with existing HDC-HE inserts with crimp, screw, tension clamp and PUSH IN connection systems.

Check them out at and search for ‘quick termination’

Weidmüller – your partner in industrial connectivity. As experienced experts, we support our customers and partners around the world with products, solutions and services in the industrial environment of power, signal and data. We are at home in their industries and markets and know the technological challenges of tomorrow. We continuously develop innovative sustainable and useful solutions for their individual needs. Together we set standards in Industrial Connectivity.

28 Oct 2019, 10:37