PROVEN RELIABILITYBenefits of safer, more reliable copper displacement terminals in power distribution systems

podis®

The global market for decentralised power distribution systems is growing rapidly and the cost saving benefits afforded by reduced labour time when installing and commissioning versus traditional wiring practices is now well established across many applications. Wieland Electric is a technology leader in this field and provides a unique tray cable solution designed to address the needs of this

growing global market: the podis® system, a robust solution that introduces copper displacement terminals.

With market leading, cost saving benefits, podis provides savings of up to 70% of labour on installation and commission with a focus on lifetime reliability and safer termination, which will be detailed further throughout this piece.

podis® Advantages

Simple configuration

Short installation times

Fast commissioning

Flexible retrofitting

Easy expansion

Less system downtime

On-sight diagnosis

Maintenance-friendly, plug connection tecnology

Optimal maintenance

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When Wieland Electric introduced podis, a power distribution system classified as a displacement connector solution, they introduced a new type of terminal for connecting to a 3-phase power conductor. In designing podis, Wieland took the concept one step further than just a standard Insulation Displacement Connector (IDC), which are used by most decentralised power distribution systems.

These systems utilise a blade termination that cuts not only the insulation but also the copper and once this type of termination has been made it cannot be removed. Doing so would reduce the rating of the power conductor due to the fact that the copper core has been cut. Attempting to remove such a termination would require the replacement of the entire power cable run.

Easier, safer termination

Typical conveyor run application example;

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Typical manufacturing process application;

Typical extended system architecture;

Designing a simpler approach for greater flexibility

Evolving away from typical applications, Wieland adopted a different approach that involved designing a single piece terminal that pierces the insulation material and then terminates with the copper cores of the conductor. This patented design avoids damaging the copper cores of the power conductor by simply pushing the conductors aside, in effect forming them around the terminal

(see image to the right). As a result, the cores are not damaged during this process while ensuring the rating of the conductor is not reduced. This process offers the benefit of allowing any tap off to be removed and moved while also offering the designer and operator of any system great flexibility for future modifications.

To assist with setup, the cable is coded (i.e. the construction has a key and cannot be installed incorrectly) and the individual terminations points are moulded into the tap off modules (see illustration to the left) with an end stop that prevents over-torqueing. Together with the keyed cable, this approach

guarantees field installations are done correctly and reliably the first time, with time saved by avoiding potential mistakes or time-consuming testing of fault-finds is realized almost immediately, especially so on larger, scaled-up projects.

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The design of the terminal and the design of the tap off module offers additional benefits. The terminal construction is such, that when used with a torque driver the termination can be considered guaranteed, which avoids the need for further inspection and commissioning compared to traditional methods. The latest generation of tap off modules also

offer a collar that allows visual inspection which ensures full compliance with UL installation standards.

UL2875 in conjunction with UL1277 allows the use of such decentralised solutions in applications and projects across North America. For additional details and support in understanding

this system and installation approval process, please contact Wieland and UL. Lifetime testing and UL product approval certification prove that this technology can be considered maintenance free for the life duration of the product. The result is a solution that does not require annual maintenance of the terminals, unlike traditional screw terminals.

Faster, fully compliant installations

System Approval UL2875, UL1277

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The unique design of the cable and tap off modules delivers class-leading installation savings. These saving can be further maximised by using the detailed version (see image to the right) with pluggable connectors (i.e. Plug & Play). If used in conjunction with pre-assembled cables that are specifically produced and tested in Wieland Electric’ ISO9001, UL98A approved production facility, no further on-site testing or commissioning is required.

Modular Cable System Assemblies and fittings for industrial control, signal and power distribution

Summary

Podis from Wieland offers up to 70% saving on installation and commissioning time, big factor on labour costs. The more complex the project, the greater the savings. Perhaps most importantly, podis offers arguably one of the safest termination and most reliable methods for connecting to a power conductor on the market. When you consider that podus is maintenance free, the benefits of improving safety and efficiency for the whole lifetime of your system are clear and realized.