Electromechanical Crimping Tools Manufactured by Klauke
uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager
Thorne & Derrick International, based in the UK, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems – this series of articles by Klauke discusses the theory and practise of installing compression type cable lugs and connectors using ratchet, hydraulic, battery-operated or electromechanical crimping tools.
Klauke cable lugs and crimping tools are used by Jointers, Linesmen, Panel Builders and Electrical Engineers to install underground cables and overhead line conductors on power, transmission and distribution networks including LV MV & HV systems, 11kV-33kV.
➡ Download 2018 Klauke Cable Lugs catalogue and see the complete range of tools for cutting and crimping cables.
In this Article we cover the advantages of using Electromechanical Crimping Tools:
It usually begins innocuously: first a numb feeling in the thumbs, index and middle fingers during the night. But then later, pain and sensory disorders throughout the day too. The hand becomes less sensitive, the fine motor skills start to dwindle and the hand gets weaker.
Day-to-day tasks become increasingly difficult and certain professional activities are difficult or even impossible to accomplish. This is caused by what is known as carpal tunnel syndrome. A nerve in the hand is permanently trapped against a constricted area that is inflamed – here are the typical signs and symptoms:
Carpal Tunnel Syndrome – Cable Crimping
One suspected cause of this widespread condition is one-sided strain, which is often encountered in the electrical trade for example. There is a good case here for taking measures to guard against such conditions and prevent expensive employee absences.
Choosing the correct electromechanical crimping tools can help reduce workplace injuries and improve site and worker Health & Safety.
One of the most commonly recurring tasks in switch cabinet construction and installing LV cable joints is the crimping of cables. This task is usually carried out using mechanical type, ratchet crimping tools and in most cases, is completed without any problem at all. It can be become critical, however, when it has to be carried out by employees on a recurring basis. With a manual force of up to 20 kilograms per crimp, excessive strain in the wrist and forearm can occur over time.
Employee Health & Safety – less physical effort with electrically-driven cable crimping tools
One key factor is considered to be the number of cable crimp operations that are carried out on a regular basis. While a young and healthy employee who has not previously experienced excessive strain can easily achieve 100 to 150 crimps per day without their health being adversely affected, the use of a cable crimping tool with motorised drive is recommended for higher numbers of repetitive crimps.
Leading manufacturers now recommend tools that allow work to be carried out much more comfortably with far less physical strain.
The electromechanical crimping tool Klauke Micro with 10.8 V lithium-ion battery, for example, requires a manual force of just two kilograms per crimp.
In other words: the force that needs to be delivered from the hand and forearm is around 90% less than that required for a crimping tool operated purely by hand.
“When we developed our Electromechanical Micro, the aim was to manufacture a cable crimping tool that is easy to use and would allow ergonomic and health-promoting work, thereby combining the benefits of a manual crimping tool with the ease of a cordless one in a single cable tool device”, explains Lutz Remmel, Product Manager at Klauke.
To make the day-to-day tasks of a qualified electrician easier and benefit from the time-saving, the selected crimping tool should cover the broadest range of tasks possible.
The electromechanical tool from Klauke is able to process cable cross-sections from 0.14 to 50sqmm with a cable crimping force of up to 15KN, with a long-term time saving compared to the mechanical crimping tool.
Because, in terms of the system concept, the electromechanical crimper tool is designed to take the interchangeable die sets from Klauke’s 50 series, it is also suitable for crimping various cable types, cable end-sleeves, and also tubular cable lugs, insulated solderless terminals and pin cable lugs.
This not only makes the cable tool a versatile companion for switch cabinet construction, it is also gentle on the installer physicals joints and allows consistently fast operations for numerous other manual, industrial and high voltage cable crimping applications.
The sequence is always the same: first, the manual pre-clamping. When the operating lever is actuated, the crimping jaws of the tool close in order to fix the electrical cable connectors.
During this particular step, the cable lug or connector material can be precisely aligned and positioned. In the second step, the cable crimp is achieved by the force of the motor.
The operating lever simply needs to be depressed fully and the crimping tool automatically starts the crimp process, which takes no more than 1.5 seconds, depending on the material.
Once the cable crimp has been made, the operating lever is released to initiate the return movement, also fully-automatic, into the original position.
Electromechanical Crimping Tool Operation
Electromechanical crimping tools reduce the physical effort, and offer the following advantages: they achieve the best crimping results for minimum force, they also guarantee the consistently high quality of these electrical connection results for years afterwards.
This is because a suitable cable crimping tool in faultless condition (properly maintained) is crucial to avoiding under-crimps and over-crimps. Otherwise, the consequences can be hazardous: incorrectly-made crimps can, for example, increase joint resistance which can in turn cause temperature rises and ultimately trigger cable fires.
When choosing a crimping tool, simple and reliable operability is the key to ensuring safety.
When Is Investment Returned?
Profitability, of course, is the question posed by any investment. The cost of a branded electromechanical crimping tool is around 180 Euro (?), or more for a manual crimping tool.
Any concerns about the durability and reliability of the electrical variant of crimping tools are unfounded. For its Micro model, for example, Klauke states a long service life if the service intervals are maintained (at 35,000 press or crimp cycles).
The cable crimping tool is equipped with a multi-function LED for maintenance display and data transfer, which can also be used to transfer crimp and tool data to a PC via a USB adapter from the tool accessories range. Test reports showing date and time can readily be created as a PDF for recording completed crimp operations. An effective way of demonstrating a safe and correct working method.
Purely mechanical manual crimping tools do not offer this option of displaying wear and creating documentation.
And also the lithium-ion batteries now used in most cable crimping tools give no cause for technical concern. These energy sources conform to a perfected technical standard that applies today in practically all sectors in which rechargeable batteries are used. Lithium-ion batteries are set apart by short charging times without memory effect and a constant, uniform power output.
The charging time for the battery installed in the Klauke tool is around 40 minutes. A fully-charged battery, can then achieve some 300 crimps on copper cables with a cross-section of 10sqmm in accordance with DIN 46234. Despite this high efficiency, the total weight of the tool, including the battery, is just 960 grammes.
Yet a far more important factor for assessing profitability, is sustaining the employee’s physical strength. The cost of sick leave due to carpal tunnel syndrome, which is mentioned at the beginning, tendinitis or tennis elbow, far outweigh those of procuring electromechanical crimping tools in the short-term.
Electromechanical crimping tools are preferred by panel builders for carrying out the termination and connection of LV MV HV cable conductors into electrical control panels.
The decision to invest in an electromechanical crimping tool should be made according to economic calculations. For specialist operations in which large numbers of electrical cable connections or cable lugs have to be processed quickly, purchasing such cable tools makes is clear sense.
Electromechanical crimping tools not only increase the efficiency of work processes but also protect the health of employees. Since maintaining good health also means sustaining physical strength, such an added investment can benefit employer and employee in equal measures. Especially in light of demographic change and the shortage of specialists this brings about, physical fitness has become an economically valuable asset which must be sustained for as long as possible.
Contact Thorne & Derrick to discuss the optimum Electromechanical Crimping Tools for your budget, application or to arrange a product demonstration.
Further Reading
Review other Blogs in this series of articles about Cable Lugs, Crimping Cables & Tools:
Cable Lugs – Crimping Applications & Standards
Copper Cable Lugs For Special Applications
Indent Crimping Of Cables – Benefits & Limitations
Cable Lugs & Crimps – Hexagonal v Indent Methods of Crimping
Cable Lugs & Crimping Using The Hexagonal Crimp Method
DIN Standard – Crimping & Compressing Aluminium Cable Lugs & Connectors
Copper & Aluminium – Crimping CU-AL Cables
Thorne & Derrick are Specialist Distributors of leading manufacturers of Cable Accessories, Jointing & Installation Equipment.
LV MV HV cable accessories used to joint, terminate, connect, cleat and gland power cables to air and gas insulated substations, transformers, switchgear and overhead line networks.
Hover over our Interactive Electricity Grid to learn more about our product ranges.
LV 600/1000V ◊ MV 11kV 33kV ◊ HV 66kV 132kV
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Substation & Overhead Line Electrical Safety Equipment
Manufactured by CATU Electrical to enable the safe construction, maintenance and repair of underground cables and overhead lines network up to EHV (400kV).
T&D - CABLES ♦ JOINTS ♦ TERMINATIONS ♦ CONNECTORS ♦ GLANDS ♦ CLEATS ♦ CRIMPS & LUGS ♦ DUCT ♦ SEALS ♦ ARC FLASH PPE
EARTHING ♦ FEEDER PILLARS ♦ JOINTERS TOOLS ♦ CABLE CUTTING & CRIMPING TOOLS ♦ COLD SHRINK ♦ HEAT SHRINK ♦ FUSES
DIN Standard – Crimping & Compressing Aluminium Cable Lugs & Connectors
uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager
Thorne & Derrick International, based in the UK, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems – this series of articles by Klauke discusses the theory and practise of installing compression type cable lugs and connectors.
Klauke cable lugs and crimping tools are used by Jointers, Linesmen, Panel Builders and Electrical Engineers to install underground cables and overhead line conductors on power, transmission and distribution networks including LV MV & HV systems, 11kV-33kV.
➡ Download 2018 Klauke Cable Lugs catalogue and see the complete range of tools for cutting and crimping cables.
In this Article we cover the following:
Best Practise for Installation
Material properties of aluminium cable are very different from those of copper cables and conductors. For safe electrical connections, solely compression cable lugs or connectors manufactured from aluminium are to be used. In addition, due to certain specific material properties the installation procedure has to be carefully observed.
The advantages of aluminium are increasingly coming to the fore in LV MV HV power distribution applications, due to the lower material weight and simple handling.
Power utilities tend to install more and more aluminium cables, for instance medium/high voltage ring main units for urban power supplies.
In principle, it is recommended to use solely high quality aluminium compression cable lugs with tube dimensions according to DIN Standard & DIN 46329 and aluminium connectors with tube dimensions according to DIN 46267 Part 2. Products of renowned cable lug and connector manufacturers such as Klauke are made from premium electrolytic aluminium alloy.
The barrier design with oil stop prevents leakage of oil from the paper insulated conductor.
These cable lugs feature a constant material thickness, exact diameter and a correct fit which ensures simple installation and absolute safety. Standard cross sections range from 10sqmm up to 500sqmm.
Installation of compression cable lugs and connectors for aluminium conductors is very different from installation of copper conductors. Failure of vital installation procedures can lead to a severe lack of safety and power outages.
Special sized cross sections are available up to 1000sqmm, for instance for subsea cables with high transmission capacities in the onshore and offshore wind and renewable energy sectors. Aluminium compression cable lugs feature a barrier design (according to DIN 46239) which allows installation on oil impregnated, paper insulated cables and consequently provides a firm water/oil block.
Aluminium conductors are available in four different types which in some cases require special installation procedures. These are as follows – should you require technical guidance, clarification or advice on crimping of aluminium cables and correct cable lugs and relating tools to use please do not hesitate to contact us:
Different types of aluminium conductors
These abbreviations can be found on aluminium compression cable lugs to make sure the correct cable lug is used with the appropriate aluminium conductor.
All markings on aluminium compression cable lugs are in conformity with those on copper cable lugs and indicate the manufacturer, dimensions and type of product.
For example marking “KL 18 10-70 /rm/sm 95 re/se” denotes:
Important: The nominal cross sections of SE and RE conductors are always one cross section size above the cross sections of SM and RM aluminium conductors.
This is due to solid conductors having a smaller diameter than their stranded equivalent type. Special attention should be given to the crimp tool and die set code.
For a professional installation the crimping dies of the appropriate crimping tool must be matched with the code of the cable lugs. Die codes on crimping dies are mirror-inverted – after the crimping operation the die code is clearly visible for quality control and documentation.
Imprint of die code “18” on the cable lug (above) indicates the crimping die used. Completed crimp (below) with marking “18” on the cable lug refers to the correct crimping die.
For a professional installation hexagonal crimping dies (according to DIN 48083 Part 4) are recommended.
Over compression (above) is the result of a crimping die which is too small, whilst under compression (middle) is caused by the use of a crimping die which is too large. The picture below shows a correct crimp using an appropriate crimping die.
The visible signs of a correctly crimped lug are the same for copper connectors as they are for aluminium.
In order to achieve a professional installation – with no over or under-crimping – the use of the appropriate cable crimping tool is essential.
An incorrect installation can result in increased joint resistance and even in fire.
To avoid such consequences Klauke recommends to use the same manufacturers tool as the lug or connector. This ensures a Matched Crimping System.
For instance the specific dies for aluminium cables have a crimping ‘bite’ width of 7mm, which is 2mm wider than for copper lugs and connectors.
The contact surface (bite width) of crimping dies for aluminium cable lugs (left) are 2 mm wider than their copper equivalent (right).
The reason for this is that wider compression areas result in better conductivity and therefore compensate for the poorer electrical properties of aluminium. In order to determine the different dies required Klauke manufacture the aluminium dies in silver and the copper dies in a yellow gold colour.
Cable lugs and connectors for aluminium are supplied with a special compound within the barrel.
Compounds with additives like corundum generate a “grinding effect”.
During crimping, this compound destroys the non-conductive oxide layer on the aluminium in the crimping area increasing the contact properties and ensuring the correct electrical connection. In addition the cable lug compound prevents entry of oxygen and consequently avoids any further oxidation.
The compound seals the joint and prevents oxidation.
To maintain the functional properties brand-name cable lugs are sealed with a plastic plug to prevent the compound from drying out and leaking from the cable lug.
Plastic plugs prevent compound from drying-out and leaking during storage.
Compounds for aluminium connectors contain additives such as corundum, a material similar to sand, which exhibits high resistance and hardness, temperature stabilising properties and extreme wear and corrosion resistance. A grinding effect is generated during crimping which cracks the hard oxide layer on the cable.
In addition, the compound aids the dynamic friction between the cable conductor and sleeve, which prevents jamming of materials and helps to provide a clean contact surface. When used on stranded conductors, the oxide inhibitor compound is distributed between the individual wires or cable strands during the crimping process and seals them against oxygen and moisture ingress.
It is also important to understand that aluminium crimp connections installed using compound perform much better when subjected to high current loads than those without compound.
To guarantee a safe connection, at high or low loads, Klauke recommends compression cable lugs and connectors with compound.
In order to accommodate the special characteristics of aluminium material, the following five installation steps are essential:
Please note: All DIN compression cable lugs show markings on the outside of the lug barrel for the correct crimp position and consequently number of crimps required. This is dependent on if the installer is using narrow or wide crimping dies.
Markings on the cable lugs indicate number and position of crimps as per manufacturers recommendation.
Always crimp in the direction of the conductor.
Start the first crimp at the lug end and progress towards the conductor to ensure that compacted material expands in this direction.
A further important technical issue is the correct method of connecting aluminium and copper conductors – contact us for the jointing, connection and splicing of dissimilar conductor cables.
Further Reading
Review other Blogs in this series of articles about Cable Lugs, Crimping Cables & Tools:
Cable Lugs – Crimping Applications & Standards
Copper Cable Lugs For Special Applications
Indent Crimping Of Cables – Benefits & Limitations
Cable Lugs & Crimps – Hexagonal v Indent Methods of Crimping
Cable Lugs & Crimping Using The Hexagonal Crimp Method
Copper & Aluminium – Crimping CU-AL Cables
Electrically Driven Crimping Tools For High Volume Applications
Thorne & Derrick are Specialist Distributors of leading manufacturers of Cable Accessories, Jointing & Installation Equipment.
LV MV HV cable accessories used to joint, terminate, connect, cleat and gland power cables to air and gas insulated substations, transformers, switchgear and overhead line networks.
Hover over our Interactive Electricity Grid to learn more about our product ranges.
LV 600/1000V ◊ MV 11kV 33kV ◊ HV 66kV 132kV
|
|
|
|
|
|
|
|
|
|
Substation & Overhead Line Electrical Safety Equipment
Manufactured by CATU Electrical to enable the safe construction, maintenance and repair of underground cables and overhead lines network up to EHV (400kV).
T&D - CABLES ♦ JOINTS ♦ TERMINATIONS ♦ CONNECTORS ♦ GLANDS ♦ CLEATS ♦ CRIMPS & LUGS ♦ DUCT ♦ SEALS ♦ ARC FLASH PPE
EARTHING ♦ FEEDER PILLARS ♦ JOINTERS TOOLS ♦ CABLE CUTTING & CRIMPING TOOLS ♦ COLD SHRINK ♦ HEAT SHRINK ♦ FUSES
Cable Lugs & Crimping Using The Hexagonal Crimp Method
uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager
Thorne & Derrick International, based in the UK, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems – this series of articles by Klauke discusses the theory and practise of installing compression type cable lugs and connectors.
Klauke cable lugs and crimping tools are used by Jointers, Linesmen, Panel Builders and Electrical Engineers to install underground cables and overhead line conductors on power, transmission and distribution networks including LV MV & HV systems, 11kV-33kV.
➡ Download 2018 Klauke Cable Lugs catalogue and see the complete range of tools for cutting and crimping cables.
In this Article we cover the following:
In daily practice hexagonal crimping is the most common kind of crimping of cable lugs and cable connectors for medium/high voltage power cables and systems.
The reason is very simple – this type of crimp is suitable for both copper and aluminium conductors. Hexagonal crimps can be found in panel building industries as a manufacturer specific crimp and also as a DIN standard lug crimp for example in utilities (aluminium and copper conductors including 11kV and 33kV power cables).
Technically the hexagonal crimp is characterised by a centrical and constant force effect applied during the crimping operation from all sides and creating a larger contact area.
Hexagonal crimps are suitable for both copper (above) and for aluminium (below)
The individual strands of the conductors are being deformed homogeneously in their entirety without any damage. The results are good electrical properties of these connections.
Mechanical and electrical properties of tubular and DIN compression cable lugs are being defined by the IEC 1238 part 1. It defines the requirements that an electrical connection has to fulfil for a permanent safe operation within intended applications.
The cross section of a hexagonal crimp performed with a manufacturer recommended tool shows the uniform positioning of conductors in the cable lug
Apart from mechanical pull out tests also electrical durability tests are included. The field of application of hexagonal crimps comprises the processing of conductors as per:
Conductor types acc. to DIN VDE 57295: round solid, round stranded, fine stranded, compacted
In addition hexagonal crimps per DIN 46235 and DIN 44267 can also be used for processing of non-tension and full tension connections of aluminium cables per DIN 48201 Part 1 of aluminium ropes per DIN EN 50182.
For processing cable lugs per DIN 46235 crimping dies with die codes per DIN 48083 can be used. This combination enables hexagonal crimps per DIN 46235 and 46267. For hexagonal crimps of standard tubular cable lugs it is suggested to strictly observe manufacturers tool recommendations.
Hexagonal crimps are exposed to high loads. For this reason only high quality tools should be used which in addition feature special functions guaranteeing correct and safe crimps. Battery powered crimping tools of the latest generation give an acoustic warning if the required crimping force has not been reached.
High quality mechanical crimping tools can only be opened when the crimping operation has been completed. Until then an integrated locking device blocks the tool – a totally completed cable crimp is important as the required compression of the crimp material is only reached at the end of the crimp phase.
A professional hexagonal crimp generally requires use of crimping dies which match sizes of conductors and connecting material. That means that cable lugs and connectors need to correspond to the dimensions of the conductor and crimping die.
 Incorrect Crimping |
 Incorrect Crimping |
 Correct Crimping |
| Incorrect and correct crimps in comparison: An incorrect crimp (crimping,middle: low force crimping, and usage of incorrect crimping tools can result in an increase in joint resistance and may jeopardise the installation) | ||
An incorrect combination can lead to low compression – excess compression crimps with potentially fatal consequences: Faulty cable crimps and lugs can lead to increased contact resistance with rise of temperatures which in the worst case can cause fire.
Incorrect or materials processed with in-appropriate tools can cause heavy defects on installations resp. electrical equipment
Cable lugs of poor quality and/or processing may cause fire
For this reason manufacturers of branded electrical and cable accessory products such as Klauke recommend for crimping operations their cable lugs and connectors solely use of their own appropriate crimping tools. High quality crimping dies can be recognised by a polished surface with rounded edges.
Example of a crimping die with polished profile
These crimping dies are precisely manufactured and guarantee a constant and neat deformation of copper or aluminium. Prior to the cable crimping operation the electrical engineer or cable joint must ensure that the conductors need to be brushed to achieve a metallic clean surface and that oxide layers have to be removed from the aluminium cables.
While stripping cable conductors it has to be observed that some are not being damaged and that bared length is more or less identical with insertion length of cable lug or connector. Crimping dies need to be clean and metallic bright. To avoid the incorrect die selection Klauke differentiates in colour, silver stands for aluminium dies and yellow gold for copper die sets.
Left: crimping die for aluminium, silver coloured; right: crimping die for copper (yellow-gold colour)
Tip: Klauke recommends to start crimping operations on cable lugs always from the palm towards the cable. In this case the compressed material can slide towards the cable end which hasn’t been crimped.
A cable lug or connector always needs to be crimped under consideration of the crimping direction and use of appropriate tools
For hexagonal crimping operations we distinguish between two versions:
Within the standard copper range the so called manufacturer specific hexagonal crimps are used for cable types as per VDE 0295 class 2.
Permissible – manufacturer specific hexagonal crimp
Manufacturers with a reputation for quality such as Klauke offer hexagonal crimping dies for processing standard copper tubular cable lugs as per EN 13600 and approved cable conductor connections as per IEC 1238.
These cable lugs are being used for instance in the construction of electrical control cabinets because of design and smaller dimensions. To accomplish a professional crimp it is of great importance to use high quality tools. Only using such tools guarantee that a sufficient degree of compression is being achieved to insure optimum contact properties.
To achieve an IEC approved connection it is necessary that all components used match each other – this includes cable lug, crimping tool and suitable die set.
This concerns the cable lug and appropriate conductor but also the suitable appropriate crimping die and crimping tool – resulting in a safety engineered system.
The classification of manufacturer specific crimping dies and cable lugs is – other than with DIN standard crimps – not controlled by die codes; it is rather regulated by the cross section of the cable specified in sqmm.
Manufacturer specific crimp with indication of cross section
Every manufacturer is responsible for the electrical durability of connections being processed with their products – specified tests have to be provided as evidence.
As a professional and safe hexagonal crimping is dependent from an exact matching of crimping dies and cable lugs Klauke recommends for crimping their cable lugs solely use of their own tools as well. In case of special applications it is advisable to involve the preferably identical manufacturer of both tools and cable lugs.
Brand manufacturers will perform – if required – for the specific application pull out tests (accelerated tests) as per IEC and where applicable also tests of the electrical contact resistance and recommend depending on the results adequate tools and materials.
In particular when it comes to international projects and processing of specific cable types for instance in China or India IEC or customer specific standards can be complied with in terms of safety.
The primary application of standardized hexagonal crimps is with electric utilities within a range from 10 kV up to 30 kV. The reason is the very homogeneous crimping which produces a consistent electrical field and consequently has a positive impact as to an unwanted field scattering.
Other than with indent crimps hexagonal crimps do not show any mechanical indent of material which in case of electrical field control needs to be balanced with a conductive compound.
Mainly for electric utilities: DIN standardised hexagonal crimp
Copper cable lugs as per DIN 46235 and copper connectors as per DIN 46267 part 1 can be crimped with crimping dies as per DIN 48083 T4.
For aluminium cable lugs as per DIN 46329 and compression connectors as per DIN 46267 part 2 and other aluminium connectors and cable lugs with appropriate tube dimensions as well hexagonal crimping dies as per DIN 48083 part 4 can be used.
Hexagonal profiles as per DIN comply with the dimensional specifications of DIN cable lugs and are standardized within given tolerances.
However, there are no specs given as to the crimp width which is either 5mm for copper or 7mm for aluminium. Identification marks on DIN cable lugs give important notes as to manufacturer, dimensions and design of cable lugs, which indicates the crimping tool resp. crimping die as necessity for crimping operations conforming to standards.
This inscription is found behind the manufacturer code.
For instance KL18 stands for
For a professional completion of a standardised crimp the tool code is decisive: The tool code of crimping die used has to conform with the tool code of the cable lug.
The imprinted tool code “18” on the cable lug (above) gives information on the crimping die to be used. The completed crimp (below) with imprint “18” on the cable lug proves that the correct crimping die was used
The die code is engraved mirror-inverted on the crimp surface of the crimping die and once crimping operation has been completed it is visible on the cable lug.
Tool codes correspond approx. with the tube dimensions of the cable lugs. For copper die codes range from 5 up to 58; this corresponds to cross sections from 6sqmm up to 1000sqm. In the same way hexagonal crimping dies for aluminium and appropriate tube dimensions of these cable lugs and connectors are standardised.
Tool code on the cable lug and imprinted code verify a correct crimp
Depending on the tool narrow or wide crimps can be used. On a cable lug of 50sqmm cross section for instance one has the alter-native to do two narrow crimps or one wide crimp.
Narrow crimp (above) and wide crimp (below)
Tools with a crimping force of up to 6t (60kN) are suitable solely for narrow hexagonal crimps of 5mm width on copper. Tools with a crimping force of more than 12t (120kN) are suitable for wide crimps according to manufacturers instruction.
Usually the electrician prefers narrow crimps as tools are lower in weight and easier to handle. For cable assembly, however, wide crimps are preferred as they reduce the number of crimps required and consequently save time.
For standard tubular cable lugs mostly narrow crimps are being used. Mechanical and battery powered tools – lower in weight – and up to 60kN are being applied.
A special feature is with aluminium cable lugs: To compensate the lower conductivity of aluminium compared with copper the narrow crimp in this case is 7mm.
Also important: The DIN standard does not prescribe a specific crimp width either for copper or for aluminium.
This information is given by the manufacturer by means of wide and narrow markings on DIN compression cable lugs. It should be observed that cable lugs resp. connectors and tools including crimping dies come from one single source, e.g. a brand manufacturer.
Crimp marking indicate to narrow resp. wide crimping
Old, but proved and tested: indent crimping constitutes the oldest type of crimping operations in electrical installations. In panel and control cabinet construction even today it is a widely used method of crimping copper – as classical indent crimp and “W” indent crimp.
Further Reading
Review other Blogs in this series of articles about Cable Lugs, Crimping Cables & Tools:
Cable Lugs – Crimping Applications & Standards
Copper Cable Lugs For Special Applications
Indent Crimping Of Cables – Benefits & Limitations
Cable Lugs & Crimps – Hexagonal v Indent Methods of Crimping
DIN Standard – Crimping & Compressing Aluminium Cable Lugs & Connectors
Copper & Aluminium – Crimping CU-AL Cables
Electrically Driven Crimping Tools For High Volume Applications
Thorne & Derrick are Specialist Distributors of leading manufacturers of Cable Accessories, Jointing & Installation Equipment.
LV MV HV cable accessories used to joint, terminate, connect, cleat and gland power cables to air and gas insulated substations, transformers, switchgear and overhead line networks.
Hover over our Interactive Electricity Grid to learn more about our product ranges.
LV 600/1000V ◊ MV 11kV 33kV ◊ HV 66kV 132kV
|
|
|
|
|
|
|
|
|
|
Substation & Overhead Line Electrical Safety Equipment
Manufactured by CATU Electrical to enable the safe construction, maintenance and repair of underground cables and overhead lines network up to EHV (400kV).
T&D - CABLES ♦ JOINTS ♦ TERMINATIONS ♦ CONNECTORS ♦ GLANDS ♦ CLEATS ♦ CRIMPS & LUGS ♦ DUCT ♦ SEALS ♦ ARC FLASH PPE
EARTHING ♦ FEEDER PILLARS ♦ JOINTERS TOOLS ♦ CABLE CUTTING & CRIMPING TOOLS ♦ COLD SHRINK ♦ HEAT SHRINK ♦ FUSES
Copper Cable Lugs For Special Applications
uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager
Thorne & Derrick International, based in the UK, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems – this series of articles by Klauke discusses the theory and practise of installing compression type cable lugs and connectors.
Klauke cable lugs and crimping tools are used by Jointers, Linesmen, Panel Builders and Electrical Engineers to install underground cables and overhead line conductors on power, transmission and distribution networks including LV MV & HV systems, 11kV-33kV.
➡ Download 2018 Klauke Cable Lugs catalogue and see the complete range of tools for cutting and crimping cables.
In this Article we cover the following:
A well known problem for every electrician or cable jointer is trying to insert a stranded or fine stranded conductor into the cable lug or cable splice and some wires cannot be inserted. To avoid this problem renowned manufacturers offer specialist application connectors and cable lugs for the jointing and termination of LV MV HV cables.
With these specialist application cable lugs all types of cables can be used – the design and construction of the cable lug to be selected is determined by the cable stranding and conductor type. The cable conductor characteristics of cable types are as classified in the DIN Standard 57295.
Class 1 is a solid/round conductor providing both the smallest diameter and largest cross-sectional area (CSA in sqmm) – this is the simplest conductor but mechanically weak with solid conductors prone to breakage after several bending cycles. The cable conductors are categorised into Classes based on the total number of strands per conductor – the higher the Class, the more strands in the conductor:
DIN 57295: DIN VDE 0295:1980-09; VDE 0295:1980-09
Conductors of Cables & Flexible Cords For Power Installation (VDE Specification)
Conductor types acc. to DIN VDE 57295: round solid, round stranded, fine stranded, compacted
The above mentioned problem of spliced cables per Class 5 and Class 6 according to DIN 57295 is being avoided when using Klauke “F” type series cable lugs. These lugs are designed for processing larger cross section conductors in voltage applications up to the short circuit tested rating of the cable lug.
Compared with standard tubular cable lugs the “F type” lugs have a larger tube diameter – the cable lugs have a flared entry which eases cable location into the barrel of the lug.
Unprofessional and individually matched cable lugs can create serious safety defects in electrical installations.
The advantages are obvious – “F type” cable lugs ensure an easy and safe insertion of the conductor, the unravelling of the cable strands is avoided and the complete conductor fits into the cable lug prior to compression using appropriate crimping tools and die sets.
Cable lugs “F type” for fine stranded conductors for easy insertion with no splicing
This is also a safety-related issue – a reduction of the cross section area of the cable conductor caused by not inserting all the strands is being avoided and the complete cross section of the cable is maintained. Markings on the F-type cable lug barrel provide information of the product, e.g. manufacturer, dimension and design.
Marking “KL 12 150 F” indicates:
For professional crimping of F-type cable lugs the indent or quad point crimping method is recommended with the appropriate crimping tools and the correct indent profile.
F-type cable lug shows professional indent crimp
To avoid over or under compression the correct tooling is a pre-requisite. An incorrect crimping connection can result in increased joint resistance leading to an increase in temperatures and in the worst case in fire.
Klauke recommends use of their own crimping tools to achieve and guarantee professional crimps according to VDE standards. In addition to “F-type” cable lugs some manufacturers offer appropriate butt-connectors for splicing, extension and repair of cable conductors.
They also feature a flared entry and larger tube dimensions. A central restriction insures uniform insertion of the cable ends, and insure the crimping recommendations for F-type lugs are adhered to.
“F-type” cable lugs and butt connectors conform to the normative requirements of the EN 13600 standard and are manufactured from electrolytic copper for excellent conductivity.
A cross sectional view of an indent crimp (with manufacturers recommended tool) shows the even arrangement of conductor in the lug
For corrosion protection the cable lugs are available tin plated from cross sections ranging between 10sqmm up to 300sqmm. In addition to the normal design “F-type” cable lugs are also available as 45° resp. 90° angled versions as well as inspection holes to check whether the conductor is fully inserted prior to crimping-up the lug using the cable tool.
As with all other connections these products are subject to test standard IEC 1238 Part 1, which guarantees a safe electrical and mechanical connection has been achieved. Cable lugs manufactured by Klauke are subject to a special annealing process to help relieve material stresses and hardness.
This reduces the chance of material fracture and is an additional safety feature. The quality of cable lugs can often be recognised by visual characteristics. A burr free lug, a flat palm and a cleanly machined end are indicative of a high quality product.
Note: IEC 61238-1:1993 Is Now Withdrawn. Compression & Mechanical Connectors For Power Cables With Ccpper Or Aluminium Conductors – Part 1. Contact T&D.
For processing and crimping solid conductors (Class 1 DIN VDE 57295) the use of tubular cable lugs “E” type is recommended which are also manufactured from electrolytic tin plated copper. Their tube diameter is matched to the conductor size to guarantee a professional cable crimp.
Professional crimp on a solid conductor with matched tube dimension
Application is in all areas where solid conductors are being mostly used, e.g. manufacture of switchgear, transformers and engines.
A hexagonal indent crimping is being recommended – again it has to be observed that both cable lugs and crimping tools come from the same manufacturer.
Cable lugs for solid conductors can be recognized by their smaller tube diameter and the marking “E”. For example: KL 10 50 E.
Cross sections usually range from 6sqmm up to 50sqmm. The range is being completed by butt-, T- and cross connectors having the appropriate internal tube diameters.
In many cases working area in switch cabinets is very tight and connecting conductors to high-power switchgears can be a problem In case of larger cross sections standard cable lugs do not fit into the compact connecting terminal.
Special cable lugs for switch cabinets (type SG) for safe connection also of conductors
For such applications many manufacturers have designed special narrow palm cable lugs (Klauke SG cable lugs) which fit comfortably.
Direct comparison of standard cable lugs (left) and cable lugs with narrow palm for switch cabinets
The narrow palm lug is also thicker than standard cable lugs ensuring the same amount of electrolytic copper has been used.
Despite a narrower palm no performance is lost. Thus these cable lugs therefore comply with a professional connection for stranded conductors according to DIN- VDE Class 2 as typically used in switch cabinets.
A hexagonal or indent crimp is recommended – conductor cross sections range from 35sqmm up to 300sqmm. The hole dimensions comply with industry sizes of connecting terminals, e.g. 6, 8, 10, 12 and 16mm.
Professional crimp on stainless steel cable lug for application in ambient temperatures of up to 400°C
Versions with inspection holes are also available – it is dangerous and incorrect to file the palm of a normal cable lug to the size of the connecting terminal. Such manipulation can result in increased temperatures and fire in the worst case.
Shows the thicker palm of SG cable lugs for switch cabinets, using the same amount of
copper as used in a standard cable lug.
Especially for adverse environments and for crimping copper conductors stainless steel and nickel tubular cable lugs have been designed. Stainless steel cable lugs are particularly acid and corrosion resistant and are typically used in chemical industries in areas exposed to sea water i.e. the earthing of masts on sailing yachts.
An additional benefit of these cable lugs is the temperature resistance. Consequently these lugs can be used in ambient temperatures up to 400°C.
At higher temperatures of up to 650°C – common in the construction of furnaces – nickel cable lugs represent the best solution. Both stainless steel and nickel cable lugs can be used for all common cable types.
A correctly crimped stainless steel cable lug used for applications where the environment can reach 400º C
Cross section ranges from 0.5sqmm up to 95sqmm. Generally an indent crimp is recommended. The same applies for stainless steel and nickel butt connectors with barrier.
Further Reading
Review other Blogs in this series of articles about Cable Lugs, Crimping Cables & Tools:
Cable Lugs – Crimping Applications & Standards
Indent Crimping Of Cables – Benefits & Limitations
Cable Lugs & Crimps – Hexagonal v Indent Methods of Crimping
Cable Lugs & Crimping Using The Hexagonal Crimp Method
DIN Standard – Crimping & Compressing Aluminium Cable Lugs & Connectors
Copper & Aluminium – Crimping CU-AL Cables
Electrically Driven Crimping Tools For High Volume Applications
Thorne & Derrick are Specialist Distributors of leading manufacturers of Cable Accessories, Jointing & Installation Equipment.
LV MV HV cable accessories used to joint, terminate, connect, cleat and gland power cables to air and gas insulated substations, transformers, switchgear and overhead line networks.
Hover over our Interactive Electricity Grid to learn more about our product ranges.
LV 600/1000V ◊ MV 11kV 33kV ◊ HV 66kV 132kV
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Substation & Overhead Line Electrical Safety Equipment
Manufactured by CATU Electrical to enable the safe construction, maintenance and repair of underground cables and overhead lines network up to EHV (400kV).
T&D - CABLES ♦ JOINTS ♦ TERMINATIONS ♦ CONNECTORS ♦ GLANDS ♦ CLEATS ♦ CRIMPS & LUGS ♦ DUCT ♦ SEALS ♦ ARC FLASH PPE
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Street Lighting Cut Outs
uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager
Lucy Zodion street lighting cut-outs are approved for use on every UK DNO Network.
Thorne & Derrick together with Lucy Zodion can offer a range of SLF street lighting cut-outs (SLCOs) which are now approved for use by every Distribution Network Operator (DNO) in the UK.
The high level of specification status of their cut-outs for street lighting applications on both the UKPN and WPD networks is a clear demonstration of Lucy Group’s commitment to keeping LV electrical connections safe and reliable.
The Lucy Zodion SLF range of street lighting cut outs use high quality materials and provide a wide range of features that help ensure robust and reliable protection and isolation across a number of street lighting network types and applications.
Additionally, the Lucy Zodion brand of Fortress type feeder pillars are extensively specified and installed throughout the UK DNO LV Electricity Distribution network.
➡ For further information about how Lucy Zodion provide control and power distribution products for street lighting applications, please review the Lucy Titan (Cut-outs) and Lucy Trojan (Isolators) ranges of products.
Here is the current street lighting cut out approval listing according to UK DNO designation:
| DNO Approved Products | DNO Area | ||
| DNO | Lucy Zodion Code |
Cut Out Description | |
| WPD* | THM0048847 | SLF IPC Type 1 HEX Drive Clear Cover (SNE) |
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| THM0041767 | SLF IPC Type 2 HEX Drive Clear Cover (CNE) |
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| ENW | 0260009009 | SLF 25A SLCO Type 1 (SNE) |  |
| 0260010009 | SLF 25A SLCO Type 2 (CNE) | ||
| NPG | THM0001978 | SLF 25A SLCO TYPE 2(CNE) POLYCARBONATE |  |
| THM0001979 | SL DNO DP 25A SLCO (CNE) POLYCARBONATE | ||
| THM0001970 | SLF 25A Single Pole SNE | ||
| SPEN | 0260009009 | SLF 25A SLCO Type 1 (SNE) |  |
| 0260010009 | SLF 25A SLCO Type 2 (CNE) | ||
| SSE | 0260009009 | SLF 25A SLCO TYPE 1 (SNE) |  |
| 0260010009 | SLF 25A SLCO TYPE 2 (CNE) | ||
| 0260026007 | SL DNO DP 25A SLCO (CNE) | ||
| UKPN* | 0260011007 | SLF 25A SLCO TYPE 1 (SNE)3mm HEXDRIVE |  |
| 0260012009 | SLF 25A SLCO TYPE 2 (CNE)3mm HEXDRIVE | ||
*sole supplier status
Street Lighting | House Service | DNO | Heavy Duty – complete range of Cut Outs
LV ♦ MV ♦ HV
T&D distribute the most extensive range of LV, MV & HV Cable Jointing, Terminating, Cable Pulling & Installation Equipment – we service UK and international clients working on underground cables, overhead lines, substations and electrical construction at LV, 11kV, 33kV and EHV transmission and distribution voltages.
LV – Low Voltage Cable Joints, Glands, Cleats, Lugs & Accessories (1000 Volts)
MV HV – Medium & High Voltage Cable Joints, Terminations & Connectors (11kV 33kV EHV)
Cable Laying – Underground Cable Covers, Ducting, Seals & Cable Pulling Equipment
T&D, CATU Electrical Safety & Arc Flash Protection Specialists for SAP’s, Linesmen, Jointers & Electrical Engineers – Largest UK Stockist
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