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Compression Cable Lugs According To DIN 46235 By Klauke
June 22nd, 2023
DIN 46235
Compression Cable Lugs
DIN 46235 is a standard that defines the applications, dimensions and the designation of compression cable lugs. Compression cable lugs according to this standard may be used for one, several, fine and super-fine stranded conductors.
The conductor design is defined in DIN EN 60228 (IEC 60228). The conductor design was previously described in VDE 0295. Copper cables according to DIN 48201-1 can also be processed using these cable lugs.
▶ 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.
When processing sector conductors, attention must be paid to ensure that the sector conductors are pre-rounded using the corresponding tool. Pre-rounding dies with the right sector sleeves are suitable for this purpose, for example.
The markings on the product provide useful information about the origin and use of the compression cable lugs – the same also applies to tubular cable lugs. Here is an example of what “KL 20 12 – 120” means:
- KL: Manufacturer code (Klauke in this particular instance)
- 20: Tool number (only for cable lugs according to DIN 46235)
- 12: Size of standard metric bolt dimensions for the connecting bolts – in this case M 12 screws
- 120: Specified nominal cross-section of conductor in mm²
3 types of lugs: DIN cable lugs, standard tubular cable lugs and sheet metal terminals (from left to right)
Compression cable lugs also have markings that provide information regarding the number and width of crimpings. The standard recommends hexagonal crimping dies according to DIN 48083-4 for processing purposes. The hexagonal dimensions are described in this standard. This means you can be sure the connection is definitely DIN-compliant.
The conductor nominal cross-sections of compression cable lugs range from 6sqmm to 1000sqmm, the hole diameter for the connecting bolt is between M5 and M20.
Compression cable lugs are made from electrolyte copper: a copper tube is shaped into a cable lug by crimping and cutting. Compression cable lugs are tin plated as standard to protect against corrosion – just like tubular cable lugs and solderless terminals. However bright finish versions are available as well.
The associated compression joint is defined in DIN 46267-1. However, the properties and processing are identical.
Cable cutting and crimping tools manufactured by Klauke are renowned for high-quality, electrical connection tools for cable crimping, cutting and punching – special cable tooling solutions for applications in a range of different sectors.
CRIMPING CABLES, LUGS & TOOLS
Thorne & Derrick distribute Cable Lugs & Cable Connectors to terminate, splice and joint LV MV HV cables – this includes copper, aluminium and bi-metallic connectors and a complete range of crimping tools for specific use on all Low, Medium & High Voltage cable types.
➡ Associated Brands & Products | Klauke | Cembre | Pfisterer Sicon | Cable Crimping & Cable Cutting Tools
Thorne & Derrick To Exhibit At SPE Offshore Europe This September
June 20th, 2023
SPE Offshore Europe
Visit Stand 1G40, HALL 1, 5th-8th September 2023
P&J Live, Aberdeen Scotland
Thorne & Derrick International are delighted to be exhibiting at SPE Offshore Europe in September this year. T&D are at the heart of our planets Energy Transition.
The transition to a sustainable energy future depends on our industry. SPE Offshore Europe helps the offshore energy value chain to accelerate the transition to a better energy future by uniting the power of expertise, knowledge and innovative technology to drive progress.
OE is a platform for collaboration, progress and results, designed by the industry for the industry, both with its year-round digital content and at its hub in Aberdeen. This is the meeting point for a community with a common purpose, expressed in the show’s strong spirit of engagement and teamwork.
“Accelerating the transition to a better energy future”
Established in 1985, T&D are Experts & Innovators of Equipment for Explosive Atmospheres to deliver technical solutions that improve safety, compliance and cost-efficiency. Specialist Distributors of LV HV Electrical Cables, Accessories & Power Distribution Products to UK and international oil/gas and renewable energy projects
We are based in North-East England, recognised as a key strategic location to service the offshore renewables energy market in the UK, from the North Sea to the Nordics – our Exports Division support international offshore wind power projects from USA to China.
We will be exhibiting Low & High Voltage Electrical Power, Heating, Ventilation, Lighting, Safety & Security Products to improve asset reliability, efficiency and safety while assisting energy transition.
We look forward to a successful event and meeting up with other Exhibitors, Customers, Suppliers and Stakeholders.
Below is a snapshot of brands that we will represent at Offshore Europe.
Specialist Distributors to the UK and international Offshore Wind & Renewable industry to provide safe and reliable LV HV Electrical Cable & Power Distribution Systems up to 66kV – we are highly customer responsive and absolutely committed to providing a world-class service.
Cable Cleats | Electrical Safety | LV HV Cable Joints & Terminations | Arc Flash PPE | Cut & Crimp Tools
Understanding client demands is key to our business strategy as is our commitment to providing fit for purpose, independent technical proposals that fulfil customer specifications. We also strive to bring product innovation to our clients to help develop safer, reliable and cost efficient working procedures.
PFAS Declaration | Ellis Patents Emperor & Vulcan Cable Cleats
June 6th, 2023
PFAS Free Cable Cleats
Perfluoroalkyl and Polyfluoroalkyl Substances (PFAS) can be found in numerous types of building products including wires and cable products due to their desirable functions such as weatherproofing, corrosion prevention, and stain resistance. However, their utility comes at a cost to health and the environment and so it is important for end users to be aware of the contents and raw materials in their products.
Ellis have released a statement to clarify that their cable cleats do not contain any PFAS or any other fluorinated substances:
“As formulated, the Ellis Emperor and Vulcan+ cable cleat do not contain any PFAS. Furthermore, we do not intentionally add any and to the best of our knowledge, the raw materials we use in these products do not contain PFAS, or any other fluorinated substances.”
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Ellis Patents Vulcan Cable Cleats |
Ellis Patents Emperor Cable Cleats |
PFas dangers & concerns
PFAS are a large class of thousands of synthetic chemicals that are used throughout society. However, they are increasingly detected as environmental pollutants and some are linked to negative effects on human health.
Perfluoroalkyl and polyfluoroalkyl substances have been recognized by various authorities as so-called “forever chemicals.” The strong fluorine-carbon bond results in products that do not readily degrade in nature, meaning that these substances become more environmentally persistent over time.
The behaviour of PFAS in the environment means that they tend to pollute groundwater and drinking water, which is difficult and costly to remediate. Certain PFAS are known to accumulate in people, animals and plants and cause toxic effects.
THORNE & DERRICK
Thorne & Derrick are national distributors of LV, MV & HV Cable Installation, Jointing, Substation & Electrical Equipment – servicing businesses involved in cabling, jointing, substation, earthing, overhead line and electrical construction at LV, 11kV, 33kV, 66kV and EHV. Supplying a complete range of power cable accessories to support the installation and maintenance of low/medium and high voltage power systems:
- Slip-on Cable Terminations
- Cold-shrink Cable Terminations
- Heat-shrink Cable Terminations
- Cable Joints – Heat & Cold-shrink
- Separable Connectors (Euromold)
- Surge Arresters & Switchgear/Transformer Bushings
Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV
The First Sustainable Arc Flash Range Of PPE From ProGARM
June 5th, 2023
ProGARM launches first sustainable range of Arc Flash Protective Clothing
Sustainable Arc Flash PPE
Introducing ProGARM’s new sustainable arc flash protective clothing range; which meets both sustainability and safety obligations.
The ProGARM range of protective garments deliver ultimate Arc Flash protection, conforming with the relevant industry and EN standards ensuring protection from Arc Flash incidents.
Thorne & Derrick provide competitive prices and fast delivery for the complete range of ProGarm arc flash clothing and accessories designed to protect people and save lives.
ProGARM are known for being arc flash specialists, and in a world-first they have launched a range which looks and performs just like their regular arc flash garments – but with a few key differences making it a truly sustainable option.
After extensive research and development working with fabric specialists across Europe, ProGARM’s new range features the maximum amount of recycled content possible while still creating a fabric and garments that meet the stringent safety standards required for arc flash protection. It uses 20% recycled fabric content, taken from off-cuts from making ProGARM’s regular range – the first arc flash range in the world to achieve this.
The first to use recycled
content in arc flash PPE
Until now it’s been difficult to use recycled content in life-saving PPE garments because of the need to guarantee protection and understand the origin of any recycled material. Using off-cuts from ProGARM’s own production and putting them back into the production process removes question marks over quality and protection levels of other recycled content which may have suffered degradation to the protection it offers.
Using this unworn fabric enables this range to have some recycled content and the same life-saving protection.
Other sustainable features include:
- Sustainable, carbon neutral packaging, made from a plant-based polymer which is a waste product from the sugar industry
- Manufactured in mainland Europe and transported by sea and land in consolidated loads. No ProGARM product travels more than 1900 miles to reach its UK destination (up to 60% less than other suppliers), with deliveries carefully planned to minimise mileage, reducing the number of deliveries by 10% in 2021/22
All of this supports organisations in minimising their impact, contributing to achieving their sustainability goals.
The sustainable arc flash protective clothing range
Meeting High Standards
Five coveralls, one jacket, and four pairs of trousers in men’s and women’s cuts make up the new range. Available in three colourways – including high-vis yellow, navy blue, and a combination of navy and high-vis yellow – the range has been designed to offer the most popular and useful garments for anyone requiring arc flash protection, while passing all relevant tests and standards.
See an overview of the range below ➡
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| ProGARM CV170F Sustainable Ladies Are Coverall | ProGARM CV170M Sustainable Arc Coverall | ProGARM TR170F Sustainability Ladies Arc Trouser | ProGARM TR170M Sustainable Arc Trouser | ProGARM CV155M Sustainable Linesman Arc Coverall |
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| ProGARM CV100F Sustainable Ladies Coverall | ProGARM CV100M Sustainable Arc Coverall | ProGARM TR120F Sustainable Arc Ladies Trouser | ProGARM TR120M Sustainable Arc Trouser | ProGARM JK128M Sustainable Arc Jacket |
Contact Thorne & Derrick to order
The range is certified for standards covering arc flash (APC1, ELIM 8cal), flame resistance (EN11612, A1 + A2), welding (EN11611), anti-static (EN1149-5), and high visibility. So it not only performs the way other arc flash garments do, but has materially less impact.
The arc flash protection is inherent, meaning it can’t be washed out and helping the workwear provide protection for longer.
ProGARM, renowned for making protective workwear which lasts up to 70% longer than the industry average, is the first company to launch a certified arc flash range containing recycled fabric.
Arc flash sustainability initiatives
The new range comes after ProGARM created the first repair programme for arc flash PPE in 2021, which helps with sustainability by making minor repairs to garment components such as zips and fastenings to extend the life of the clothing.
With arc flash clothing, even a small rip which happens during the rigorous workday of the wearer would mean it no longer offered the life-saving protection needed, and would mean it had to be thrown away. The combination of ProGARM’s focus on durability and the option for small repairs to fastenings means their range can last up to 70% longer than competitor options.
The company has also partnered with a leading textile recycler to offer end-of-life recycling for all its products so they can be recycled, making sure ProGARM products don’t become part of the 350,000 tonnes of textile waste send to landfill in the UK every year.
ProGARM aims to be carbon neutral throughout all its operations and the whole supply chain (scopes 1, 2 and 3) by the end of 2025.
ARC FLASH LEARNING & RESOURCES
Thorne and Derrick are proud to be distributors of ProGARM arc flash coveralls and protection.
We can help – should you require arc flash calculators or advice on the type of clothing and protection available please do not hesitate to contact us.
PADS Approved Temporary Rail Jumper Kit | PBwel
June 5th, 2023
Temporary Rail Jumper Kit
PADS Approved 0006/120053
The PBwel Temporary Rail Jumper Kit allows faulty equipment such as switches to be by-passed, in order to maintain the network until repairs can be made to return the asset to service. The EFT-19319 kit is suitable to by-pass a continual traction load of 600A even upon heavily weathered overhead conductors.
The kit is accepted for use on Network Rail controlled 25kV OLE infrastructure with PADS approval 0006/120053.
Each kit comprises of three 120mm² clear Aluflex lead assemblies with heavy duty terminations fitted to special S9B Line End clamps.
💡 Thorne & Derrick, the UK Preferred Distributor for P&B Weir Electrical Ltd (PBwel), are now stocking their range of Rail Earthing Equipment with PADS Approval for use on Network Rail high voltage electrification projects. This significant and strategic stock holding is the culmination of discussions and planning to support framework contractors and construction alliances during and beyond the current CP6 plan. 💡
Portable Full Current Jumper Kit
The Portable Full Current Jumper kit utilises the original P&B (PBwel) S9B Line End clamp, which has been used by Network Rail/ Railtrack/ British Rail for many decades and has a proven record for reliability and performance.
The clamps are lightweight and compatible with standard operating poles. The addition of a serrated jaw has proven to ensure good contact with dirty/weathered conductors and provides sufficient capacity to carry full traction current over an extended period.
Continuous Current Rating – 600A
Short Circuit Rating- 54kA/1sec
Order of Application and Removal
Site rules and PPE requirements should be fully understood and adhered to when using this kit. Possession and de-energisation should be sought according to procedures and an Authorised Person should also determine where the kit should be safely applied.
The conductor should be tested for absence of Line Voltage prior to fitting the kit.
Each lead should be applied in turn, with two Overhead Line Engineers raising and applying both S9B clamps at the same time, using two operating poles. Care should be taken to ensure that both clamps are securely fitted onto the conductor/ armour rods.
Failure to do this could result in a poor current path or (under severe circumstances) several hanging leads, which if subjected to a fault could pose a risk of serious danger.
PB120T terminations are employed to suit the application, which allows the kit to be distinguished from standard earths.
Application and Removal of the S9B Clamp
The operating screw of the S9B Line End clamp should be firmly inserted into the operating socket until the spring action of the socket holds the clamp in place, this is a bayonet style fitting and the cross-pin of the operating screw should be correctly located.
The clamp should then be raised towards the conductor or arm our rod and hooked over, so that the conductor/armour rod sits between the jaw and the body of the S9B. The clamp should then be firmly tightened onto the conductor/armour rod by rotating the operating pole in a clockwise direction.
At this point, the pole can be removed by firmly lifting the pole and rotating it in an anti-clockwise direction, before slowly lowering the pole to dis-engage the clamp from the socket. The pole should then be carefully lowered to the ground making sure all staff are clear of the area intended for ‘landing’.
Application of S9B Clamp
When removing the clamp, the pole should be carefully raised and the operating screw of the clamp inserted into the centre of the socket. The pole should be firmly pressed in an upward direction as the pole will freely lift a small amount. Once engaged the pole may be rotated anti-clockwise to loosen the clamp from the conductor.
Once sufficiently loose (it is recommended the clamp is fully opened and ‘pinched’ tight, to aid control) the pole may be lifted to raise the clamp off of the conductor before carefully lowering to the ground.
Removal of S9B Clamp
Thorne & Derrick supply an extensive range of 400V-33kV Rail Cable Accessories & Power Distribution Sytems including feeder pillars to contractors undertaking Low Voltage Power Distribution, HV Electrification & Substations, DC Traction & Networks, OLE and Track Feeder Cable Renewals – a complete range of Network Rail PADS approved track terminations, cable joints, cable repair and connection products up to 25kV, including 3M Cold Shrink, Pfisterer CONNEX and Nexans Euromold products.
Heat shrink, cold shrink, push-on and slip-over cable accessories enable the jointing, terminating and connection of medium/high voltage power cables to oil, air or gas insulated switchgear, transformers, motors and overhead lines.
Full range of Cable Pulling Equipment & Products to ensure safe and efficient of rail cables in to cable ducts and containment infrastructure including cable troughs.
Reliable & Compliant Cable Accessories for Substation, Trackside & OHL Power Supply
Contact us for a Quotation for Rail Earthing Equipment
