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APPLICATION
GUIDELINE FOR
TERMINAL BLOCKS
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Published by:
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© Copyright 2010 by the National Electrical Manufacturers Association. All rights including translation into
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Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions.
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The information in this publication was considered technically sound by the consensus of persons
engaged in the development and approval of the document at the time it was developed. Consensus
does not necessarily mean that there is unanimous agreement among every person participating in the
development of this document.
The National Electrical Manufacturers Association (NEMA) standards and guideline publications, of which
the document contained herein is one, are developed through a voluntary consensus standards
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exercise of reasonable care in any given circumstances. Information and other standards on the topic
covered by this publication may be available from other sources, which the user may wish to consult for
additional views or information not covered by this publication.
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NEMA has no power, nor does it undertake to police or enforce compliance with the contents of this
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of the statement.
CONTENTS
Foreword ......................................................................................................................................................... ii
Introduction .................................................................................................................................................... iv
History ............................................................................................................................................................ iv
Section 1 GENERAL.................................................................................................................................... 1
1.1 Referenced Standards........................................................................................................................... 1
1.2 Scope...................................................................................................................................................... 2
1.3 Normative References ........................................................................................................................... 3
Section 2 DEFINITIONS .............................................................................................................................. 4
Section 3 CLASSIFICATION ....................................................................................................................... 6
Section 4 CHARACTERISTICS AND RATINGS......................................................................................... 7
Section 5 PRODUCT MARKING, INSTALLATION, AND MAINTENANCE INFORMATION .................... 8
5.1 Product Information................................................................................................................................ 8
5.1.1 Connecting Capacity................................................................................................................. 8
5.1.2 Mandatory Product Information ................................................................................................ 8
Section 6 CONSTRUCTION ........................................................................................................................ 9
6.1 Terminal Assemblies ............................................................................................................................. 9
6.1.1 Mechanical and Electrical Connection of Conductors ............................................................. 9
6.1.2 Terminal Assembly Material .....................................................................................................9
6.1.3 Protective Coating of Terminal Assembly ................................................................................ 9
6.1.4 Clamping of Conductors ........................................................................................................... 9
6.2 Mounting Means..................................................................................................................................... 9
6.3 Identification ........................................................................................................................................... 9
6.4 Clearance and Creepage Distances..................................................................................................... 9
Section 7 PERFORMANCE REQUIREMENTS AND TESTS ................................................................... 10
7.1 Design (Type) Tests, General .............................................................................................................10
7.2 Test Conditions ....................................................................................................................................10
7.2.1 Test Conductors......................................................................................................................10
7.2.2 Conductor Ends ......................................................................................................................10
7.2.3 Terminal Block Mounting ........................................................................................................10
7.2.4 Condition of Unit under Test...................................................................................................10
7.3 Test Sequence .....................................................................................................................................10
7.4 Type Tests............................................................................................................................................10
7.4.1 Clamping Unit and Terminal Assembly Test..........................................................................10
7.4.2 Voltage Drop Test ...................................................................................................................10
7.4.3 Secureness Test .....................................................................................................................11
7.4.4 Pull Test...................................................................................................................................11
7.4.5 Temperature Rise Test ...........................................................................................................11
7.4.6 Dielectric Strength...................................................................................................................11
7.4.7 Current-Cycling Tests .............................................................................................................11
7.4.8 Thermoplastic Insulator Stress Relief Test ............................................................................11
Section 8 APPLICATIONS ........................................................................................................................ 12
8.1 Application of Terminal Blocks in Hazardous Locations ...................................................................12
8.1.1 Definition..................................................................................................................................12
8.1.2 Installations .............................................................................................................................12
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Foreword
This Applications Guideline was prepared by a technical committee of the NEMA Industrial Automation
Control Products and Systems Section. It was approved in accordance with the bylaws of NEMA.
This Applications Guideline provides practical information concerning ratings, construction, test,
performance, and manufacture of industrial control equipment. This publication is used by the electrical
industry to provide guidelines for the manufacture and proper application of reliable products and
equipment and to promote the benefits of repetitive manufacturing and widespread product availability.
NEMA Applications Guidelines represent the result of many years of research, investigation, and
experience by the members of NEMA, its predecessors, and its sections and committees. They have
been developed through continuing consultation among manufacturers, users, and national engineering
societies and have resulted in improved serviceability of electrical products with economies to
manufacturers and users.
One of the primary purposes of this Applications Guideline is to encourage the production of reliable
control equipment, which, in itself, functions in accordance with accepted standards. Properly constructed
industrial control equipment is, however, only one factor in minimizing the hazards that may be
associated with the use of electricity. The reduction of hazard involves the joint efforts of the various
equipment manufacturers, the system designer, the installer, and the user. Information is provided herein
to assist users and others in the proper selection of control equipment.
The industrial control manufacturer has limited or no control over the following factors, which are vital to a
safe installation:
a. Environmental conditions
b. System design
c. Equipment selection and application
d. Installation
e. Operating practices
f. Maintenance
This publication is not intended to instruct the user of control equipment with regard to these factors
except insofar as suitable equipment to meet needs can be recognized in this publication and some
application guidance is given.
This Applications Guideline is necessarily confined to defining the construction requirements for industrial
control equipment and to providing recommendations for proper selection for use under normal or certain
specific conditions. Since any piece of industrial control equipment can be installed, operated, and
maintained in such a manner that hazardous conditions may result, conformance with this publication
does not by itself ensure a safe installation. When, however, equipment conforming to this Applications
Guideline is properly selected and is installed in accordance with the National Electrical Code and is
properly maintained, the hazards to persons and property will be reduced.
To continue to serve the best interests of users of industrial control and systems equipment, the Industrial
Automation Control Products and Systems Section is actively cooperating with other standardization
organizations in the development of simple and more universal metrology practices. In this publication,
the U.S. customary units are gradually being supplemented by those of the modernized metric system
known as the International System of Units (SI). This transition involves no changes in standard
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NEMA Applications Guidelines are subject to periodic review. They are revised frequently to reflect user
input and to meet changing conditions and technical progress. Users should secure the latest editions.
Proposed revisions to this Applications Guideline should be submitted to:
Section approval of the Applications Guideline does not necessarily imply that all section members voted
for its approval or participated in its development. At the time it was approved, the section was composed
of the following members:
Introduction
The standards pertaining to terminal blocks in NEMA Applications Guideline ICS 4 are subdivided into the
following sections:
1 General
Referenced Standards
Scope
Normative References
2 Definitions
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Terms that supplement the IEC International Electrotechnical Vocabulary (IEV 441) or assist
in clarifying the product standard.
3 Classification
Product classifications where they have been established.
6 Construction
Marking, color coding, and similar production requirements to be incorporated into the product
as manufactured, as well as production test requirements where they have been established,
i.e., the rules that the manufacturer follows in producing the product.
8 Applications
Information and performance considerations of importance to those who specify or use the
product.
History
This standard replaces ICS 4-2005. The decision to initiate a program to convert ICS 4-2005 into an
Application Guideline was based on the fact that ICS 4-2005 duplicated descriptions of tests as found in
UL 1059, UL 486E, and the IEC 60947-7-X series of standards.
Section 1
GENERAL
ICS 1-2000 (R2005, R2008) Industrial Control and Systems: General Requirements
UL 486E Equipment Wiring Terminals for Use with Aluminum and/or Copper
Conductors
ISA
67 Alexander Drive
Research Triangle Park, NC 27709
1.2 SCOPE
This Applications Guideline applies to one piece, or modular, or two piece terminal blocks with screw-
type, screwless-type, or insulation displacement clamping units intended for industrial use, and fixed to a
support or to a Printed Circuit Board (PCB) to provide electrical and mechanical connection for the
following round, solid, or stranded conductors:
a. Copper conductors only, without special preparation, having a cross-section of 24 AWG to 2000
kcmil (0.2 to 1014 mm2), or 30 AWG to 8 AWG (0.05 to 8.37 mm2) for Printed Circuit Board
(PCB) terminal blocks.
c. Aluminum (uncoated) and copper conductors, without special preparation, having a cross-
section of 12 AWG to 6 AWG (2.5 to 16 mm2) for solid conductors and of 12 AWG to 2000 kcmil
(3.3 to 1014 mm2) for stranded conductors.
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The terminal blocks are intended for use in circuits of rated insulation voltage not exceeding 1000 V ac at
a frequency not greater than 60 hertz, or not exceeding 1500 V dc.
This Applications Guideline does not apply to connectors specifically designed for, and forming, an
integral part of equipment, which are dealt with in the relevant equipment standards.
NOTE—This Applications Guideline may be used as a guide for the termination requirements for disconnect type or other special
terminal blocks for which there is no standard at this time.
Section 2
DEFINITIONS
For the purpose of this standards publication, the following definitions apply:
clamping unit: The part(s) of a terminal necessary for the mechanical clamping and the electrical
connection of the conductor(s).
clearance: The distance between two conductive parts along a string stretched the shortest way between
these conductive parts.
connecting capability: A range or number, or both, of connectable conductor cross-sections for which
the terminal block is designed.
creepage distance: The shortest distance along the surface of an insulating material between two
conductive parts. A joint between two pieces of insulating material is considered part of the surface.
printed circuit board (PCB) terminal block: A one piece, or modular, or two piece terminal block fixed
to a printed circuit board by soldering or other suitable means.
rated cross-section: A value of connectable conductor cross-section, stated by the manufacturer and to
which certain thermal, mechanical, and electrical requirements are referred.
rated insulation voltage: The value of voltage, Ui, stated by the manufacturer, by which the terminal
block is designated and to which the electrical tests, clearance, and creepage distances are referred. In
no case shall the maximum value of the rated operational voltage exceed that of the rated insulation
voltage.
NOTE—For equipment not having a specified rated insulation voltage, the highest value of the rated operational voltage is
considered to be the rated insulation voltage.
screw-type terminal: A terminal for the connection and subsequent disconnection of a conductor or the
interconnection of two or more conductors capable of being dismantled, the connection being made,
directly or indirectly, by means of screws or nuts of any kind.
screwless-type terminal: A terminal for the connection and subsequent disconnection of a conductor or
the interconnection of two or more conductors capable of being dismantled, the connection being made,
directly or indirectly, by means of springs, wedges, eccentrics, or cones.
special preparation (of conductor end): Alteration of the manufactured shape or surface of the
conductor to enable it to be connected to the terminal.
NOTE—This definition differs from IEC 60947-7-1, in which “Special Preparation” means the use of crimped ferrules and similar
terminal devices.
terminal: A conductive part of a device, provided for electrical connection to external circuits.
terminal assembly: One or more terminals fixed to the same conductive part.
terminal block: An insulating part carrying one or more mutually insulated terminal assemblies and
intended to be fixed to a support.
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terminal insulator: An insulating part intended for maintaining in position or for covering live parts.
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Section 3
CLASSIFICATION
a. Method of fixing the terminal blocks to a support or to a printed circuit board (PCB)
b. Number of terminal assemblies
c. Type of terminals, for example, screw-type terminals and screwless-type terminals
d. Ability to receive conductors having particular terminations, for example, cable lugs
e. Terminal assemblies with identical or dissimilar clamping units
f. Number of terminals on each terminal assembly
g. Two piece, separable terminal blocks
h. Service conditions
i. Terminal blocks, suitable for the connection of copper conductors only (marked Cu)
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j. Terminal blocks, suitable for the connection of aluminum conductors only (marked Al)
k. Terminal blocks, suitable for the connection of aluminum conductors as well as copper
conductors (marked Al-Cu)
Section 4
CHARACTERISTICS AND RATINGS
The terminal block shall be rated in terms of the maximum cross-section of a single 75°C insulated
conductor.
Section 5
PRODUCT MARKING, INSTALLATION, AND MAINTENANCE INFORMATION
The following product information shall be marked either on the terminal block or contained in the
manufacturer's data sheet or on the smallest packing unit:
a. The rated cross-section and the thermal rating of the conductor, if other than 75°C
NOTE—Tests in this standard are based on conductor ratings corresponding to 75°C thermal insulation rating and
30°C ambient. Results are also applicable to conductors of the same cross-section and any higher thermal insulation
rating.
b. The connecting capacity, including the type and number of conductors simultaneously
connectable
c. The tightening torque values for the clamping screws
d. Rated insulation voltage
e. Service conditions if different from those stated in ICS 1, Part 6
f. Marking "Cu" for terminal blocks used for copper conductors only
g. Marking "Al" for terminal blocks used for aluminum conductors only
h. Marking "Al-Cu" for terminal blocks suitable for the connection of aluminum or copper
conductors
Section 6
CONSTRUCTION
a. Aluminum or aluminum alloy terminal assemblies used only for the connection of aluminum
conductors
b. Copper or copper alloy terminal assemblies used only for the connection of copper conductors
Where protective coating is necessary, tin coating is acceptable for all combinations of terminal
assemblies, including the clamping screws.
6.3 IDENTIFICATION
A terminal block shall be permitted to have provisions for identification marks or numbers for each
terminal or terminal assembly to be related to the circuit of which it is to form a part.
Section 7
PERFORMANCE REQUIREMENTS AND TESTS
A particular design of terminal block, having one or more terminal assemblies, shall be permitted to be
manufactured. Unless otherwise specified, terminal blocks with any number of terminal assemblies are
permitted to be submitted for the tests.
For a range of terminal sizes of similar design, the largest, smallest, and 2 intermediate sizes shall be
tested; except that for a range of 3 terminal sizes, the largest and the smallest, and for ranges of 4 and 5
sizes, the largest, smallest, and one intermediate size, need only be tested. A range of terminals is similar
if all have the following common features:
a. Shape of terminal, shape of conductor opening, and shape of wire clamping screw
b. Material and coating of terminal body
c. Material of wire clamping screw
d. Quantity of clamping screws
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Section 8
APPLICATIONS
8.1.1 Definition
Hazardous locations are defined in the National Electrical Code, Articles 500 & 505.
8.1.2 Installations
The safe application of terminal blocks in these locations requires the correct determination of the hazard,
division, or zone and the selection of the proper enclosure. The user is advised to carefully consult the
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following references.
ANSI/ISA 60079-7-2008 Electrical Equipment for Use in Class I, Zone 1 Hazardous (Classified)
Locations: Type of Protection—Increased Safety “e”