Cable Crimping – Lugs & Tools

Cable Lugs | How To Choose The Right One?

Thorne & Derrick | Distributed from Stock | Approved Supplier | UK & Export Sales

Klauke Cable lugs

The choice of cable lugs available for all kinds of applications in the electrical sector is huge.

Making the right choice can be harder than you might think. However, choosing the right lug is essential to ensuring a clean and secure crimping result.

This overview provides a more detailed insight into the most common lugs for copper conductors, helping explain to you what you need to look out for when making your choice so that your connection will indeed be secure and long-lasting.

Cable lugs for copper conductors, connected to the conductor by way of so-called cold forming, are some of the most common connectors in electrical engineering.

They can be roughly divided into three groups:

• Compression cable lugs according to DIN 46235 
• Tubular cable lugs as commercially available standard types
• Solderless terminals according to DIN 46234

Cable & cable lug: the perfect pair

Choosing the right cable lug also depends on the conductor class to be processed. As an example, the following cable lug types are available for cables according to DIN EN 60228:

• Class 1, 2, 5 and 6 conductors: compression cable lugs according to DIN 46235
• Class 2 conductors: standard type tubular cable lugs
• Class 2, 5 and 6 conductors: solderless terminals according to DIN 46234

To ensure safe crimping of conductors using DIN compression cable lugs, crimping tools with coded dies according to DIN 48083-4 are recommended in the standard. The requirements of the respective manufacturer must be observed for tubular cable lugs.

Solderless terminals according to DIN 46234 are processing using indent crimping.

Quality and resistance: on the test bench

Standards also apply to the electrical and mechanical properties of cable lugs. The international standard IEC 61238-1 part 1 applies in this particular instance. It specifies the tests that an electrical connection needs to fulfil in order to ensure long-term safe operation for its intended use.

The electrical connections must undergo different tests for this purpose. This involves an electrical durability test alongside a mechanical tension test. A test cycle simulates a practical application in this test.

Electricity is used to heat up the connection 1000 times to approx. 120 °C in order to bring about artificial ageing. The contact resistance is reviewed at regular intervals in between the tests.

Six high current tests are also carried out where the conductor is heated up to approx. 250°C in one second thanks to a short circuit. This high current test is required if the connector is due to be tested to check it is short-circuit protected.

The Klauke connecting material has also passed this test. The crimping connection passes the test if the contact resistance remained constant throughout.

Manufacturers are responsible for being able to guarantee the safety of their connections. With these additional tests that are carried out, you can rest assured that our connecting material satisfies the highest demands.

In addition, a significant amount of our materials are UL-tested and certified. This is particularly useful when control cabinets are to be supplied to North America, for example.

Electrical and mechanical properties of cable lugs

However, we also place additional requirements on the quality of our products that go beyond these standard requirements. Cable lugs made by Klauke are annealed as part of an additional manufacturing stage. This means we can reduce any hardening and tension in the material, as well as reduce the risk of breaking during crimping.

The quality of our cable lugs is already evident from their visual characteristics. Burr-free production and a consistently flat palm are signs of a high-quality product – likewise clean final machining of the tube section.

Contact our Sales Team for prices, technical support or to place an order for cable lugs or installation tooling for cutting and crimping cables manufactured by market-leader Klauke.

Klauke cable lugs and crimping tools are used by Jointers, Linemen, 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.

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 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

Should you require technical assistance to select the correct cable crimping or cable cutting tools please contact us.

Thorne & Derrick are Specialist Distributors of cable tools to enable the preparation of all LV MV HV cables prior to the installation of Joints, Terminations & Connectors – this includes Klauke, Cembre, Alroc and Boddingtons cable jointing tools for removal of cable sheath, screen and insulation on 11/33kV (MV) and 66kV/132kV (HV) power cables.

View the complete range of Cable Crimping & Cable Cutting Tools

Catenary Wire Straighteners | Tools to Remove Kinks from Overhead Rail Cables

Catenary Wire Straighteners

Tools to Remove Kinks from Overhead Line & Catenary

The Hydraulic Kink Remover is used to straighten out areas on the contact wire that have developed ‘kinks’ on the UK rail electrification networks. This ensures that the overhead wire is continuously in contact with the pantograph. The catenary wire straighteners are specifically designed for maintenance use on overhead rail cables.

Battery Tool

BDL041 

• Battery or cordless tool powered by a 18V, 2.0Ah or 5.0Ah Li-Ion battery
• Removable steel frame to position the tool on the wire to be straightened
• Locked in place by a powerful spring
• Suitable for 107sqmm and 150sqmm contact wires
• Head can be rotated through 180^o, equipped with a handle that can be screwed onto either side of the tool
• Ergonomically designed & well balanced
• On/off button, with switching to standby after 10 min
• Quick motor stop after cycle for greater safety
• Piston returns manually by release trigger
• Electronic overpressure protection
• LED to indicate maintenance, the battery charge level and the maximum tool pressure as it is reached

Railway Tools – The Electric System

The delivery of electricity to railways is usually through a system of overhead lines. This is called a catenary. Meanwhile, transmission to the trains is through a Pantograph. This a framework which collects power and passes it through to the motors. One of the key maintenance issues is that there is a lot of movement in the cables. This is hardly a surprise given the high speeds of modern trains. As a result, the Pantograph adjusts its position to remain in contact with the overhead line.

Maintaining the Catenary involves regular inspection and repair. In particular, this involves the removal of any ‘kinks’ that develop in the line.

Hydraulic Head

XDH41

• Head powered by a 700 bar power pack, connected via a high pressure hose
• Removable steel frame to position the tool on the wire to be straightened
• Locked in place by a powerful spring
• Suitable for 107mm² and 150mm² contact wires

Railway Tools – Maintenance

Much of the work on overhead lines involves high-level maintenance trains.  Above all, they provide a stable platform to work from. Moreover, they provide the hydraulic power needed for the XDH41. For remote or emergency works, where a maintenance train is not available, there is the Stanley Dubuis BDL41. This battery tool shares the same in-line ergonomic handle as the Stanley Dubuis cable cutting and crimping tools.

Likewise, it uses the 18 volt 5.0Ah DeWalt/Stanley batteries, common to the whole range.

Technical Specifications

RAIL CABLE ACCESSORIES, ELECTRIFICATION

& INSTALLATION EQUIPMENT

Thorne & Derrick supply an extensive range of 400V-66kV Rail Cable Accessories & Power Distribution Systems 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.

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

Cembre | New Generation “Bilinear” Cordless Crimping Tools Available From Thorne & Derrick

Cembre “Bilinear” Cordless Battery Crimping Tools

CEMBRE Bilinear Cordless Crimping Tools

ND Series, Battery Crimping Tools 18.0V – 2.0 Ah

Cembre have launched a new generation of hand-held cordless battery crimping tools, characterised by a “Bilinear” mechanical design. Operator comfort and convenience are key factors in producing repeatedly consistent high integrity crimped joints.

Thorne & Derrick supply the Cembre ‘ND Series’ of bilinear tools. They have their mechanical centre of gravity nearest to the operator’s wrist to optimise the overall ergonomics of the tool and provide a wider support for the hand.

Thus the innovative misalignment between the pump drive mechanism and the hydraulic system both reduce the torque generated on the operator’s wrist and best distribute the stresses acting on the hand.

➡ Cembre offer a complete range of battery operated cable crimping tools for use with crimps, connectors and lugs up to 400sqmm including medium/high voltage cables at 11kV/33kV.

“Bilinear” Cordless Crimping Tools Features

Smart Release System

“Smart Release Technology” is a new development by Cembre whereby an intelligent oil pressure release system stops the motor at the end of the crimping cycle.  Automatic retraction of the ram only occurs when the operator releases the start button, this allows visual verification of the jaws to ensure that they have fully met prior to releasing.

Similar tools with ‘standard’ automatic return do not permit this visual verification that full compression has taken place before releasing pressure.

Electronic Pressure Sensor (EPS)

The Electronic Pressure Sensor (EPS) guarantees the precision of the crimping operation, checking the actual value of pressure and informing the operator about possible errors.

Smart Tool Technology

Data recording and intelligent control allow complete verification of operational parameters. SMARTOOL technology enables the user to to store data from up to 200,000 cycles on the integrated memory card for transfer to a computer via a USB cable.

New two-speed hydraulic system

On the new generation of tools, a dual speed hydraulic system has been implemented with the double concentric pumping system and interlocked spring, the original patented solution by Cembre.

Faster compression and greater crimping force result from the new two-speed hydraulic system: a high approach speed which automatically switches to a low crimping speed, ensuring optimal use of the available energy.

New Multifunction OLED Display With Touch Button

Equipped with Li-Ion 18 V-2Ah rechargeable high capacity batteries. Fitted with a maximum pressure sensor for enhanced precision and repeatability of the maximum pressure cycle, and a pressure relief valve providing additional safety for the operator.  Weight and balance have been reconfigured to yield improvements in handling and convenience.

The more rigid structure of the bi-component plastic body provides greater mechanical protection while its  rubber inserts boost operator safety and comfort.  Quieter operation, illumination of the working area via LED lights and a minimum of vibration enhance the tool’s practicality.

“Bilinear” Cordless Crimping Tools

Operating Features of the Tools

• Bilinear mechanical design
• Smart Release system to automatically retract the ram at the end of the crimping cycle
• OLED multifunctional display with touch button
• Electronic Pressure Sensor (EPS)
• SMARTOOL technology for viewing and downloading operational data
• 180° rotating head
• Start button protected against accidental operation
• Manual pressure release button
• Illumination of working area via 4 x LED lights
• Bi-component plastic body
• Ergonomic design for operator comfort
• Li-Ion 18.0 V-2Ah rechargeable high capacity battery
• Battery connection system with release button

18V Handheld Cordless Hydraulic Tool With Bilinear Structure I Cembre B-FL750ND

LV Lugs & Connectors – complete range of copper crimp connectors suitable for use with joints and terminations for low voltage cables | Cable Lugs | Cable Splice Connectors | Aluminium Lugs | Aluminium Splices | Bi-Metallic Cable Lugs

Thorne & Derrick

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 HV | Cold Shrink

Work Smarter, Not Harder | Using The Most Efficient Ridgid Tools

Versatile tools save you time and money on the job. For example, RP 342-XL press tool, shown here with the StrutSlayr Strut Shear Head, works with all of the RIDGID press tool accessories.

Cut Down Time On Your Jobsite

In today’s high-tech world, when people talk about tool timesavers they tend to focus on the latest Bluetooth technology or the newest gadget. Yet, technology is not the only way to cut down time on a jobsite: tools that allow you to work smarter, not harder, can help any professional get to the next jobsite more effectively and efficiently.

Here are a few questions to consider when evaluating the timesaving merits of a tool.

Can the tool do more than one job? 

Anytime you can rely on a tool to perform more than one task, that is a win – you will reach in your toolbox less and have less to haul onto a jobsite. The best tools seem to help you do more with less: less gear, less time, less looking around. For example, some wrenches provide multiple surface wrench sizes on one side and have an open box-end for line nuts. This type of wrench has you covered for straight stops, appliance legs, shower heads, faucet nuts, stool bolts, and more. 

Are you maximizing the tool’s versatility?

A key factor when saving time and limiting redundancy in your toolbox is to have knowledge of a tool’s full ability. Pressing tools are a good example: Plumbers appreciate press tools because they save time on connections and eliminate the need for soldering. Some press tools can do more than just press pipe connections. For example, RIDGID tools have designed their press tools to be multipurpose. Understanding that no two jobs are created equal, RIDGID tools built the RP 342-XL for them all: its versatile design packs major power and boasts the widest range of applications of any press tool. It can press 1/2” to 4” copper, stainless steel, and carbon steel pipe and 1/2” to 2” PEX—in less than 10 seconds. It is also compatible with the full line of RIDGID Standard 32kN press tool accessories, including the StrutSlayr™ Strut Shear Head, Press Snap™ Soil Pipe Cutter, and all MegaPress jaws. 

➡ STRUTSLAYR tool is designed to mechanically shear steel strut channels up to a maximum size of 41 x 41mm, thickness 2.5mm. Compatible with RIDGID 32kN press tools*, the STRUTSLAYR strut cutter offers reduced risk sparking when compared to grinders and chop saws and still manages to produce a clean, consistent cut just by pulling the trigger – a cutting-edge innovation.

How reliable are the tools you buy? 

Any tool is a timesaver if it is reliable. Think about the tools you have owned the longest. Which tools push through a hard job without breaking? What brand is a one- or two-year tool versus a lifetime of performance? When you are constantly having tools break down and you are investing time and money to replace or repair them, that is a waste.

Buying reliable, proven tools is the best timesaver (and moneymaker). A strong warranty program is nice, but if the tool is always breaking—even if the repairs are free—that downtime will cost you money every time. 

Are you buying tools for today or tomorrow? 

This question builds on the issue of reliability. Sometimes cost is a hard line that you cannot cross; but when you can, always consider your long-term plans. You might buy a smaller drain cleaner because it costs less. Yet, you know that the larger commercial drain cleaner will allow you to do 10 times as many jobs and build your business in the future.

Which is a better investment? Tool redundancy has its place, but for higher-cost items, it can be a drain on expenses and a sore spot if your small drain cleaner is collecting dust in a warehouse a year from now. 

Will I have to start from scratch when I need to upgrade?

When you buy equipment to meet your immediate needs, consider whether there are products designed to complement the equipment as you upgrade. For example, RIDGID reels, imaging cameras, monitors, locators, recorders, and drain cleaning equipment are designed to work together, so setup time is fast and compatibility is a given. Along with faster setup time, purchasing tools that integrate with each other can save you money and minimise downtime for training. 

Saving time equals more jobs, and that means more income. There are many ways to adjust your tool inventory so you can work smarter, not harder. 

CABLE TOOLS

Should you require technical assistance to select the correct cable crimping or cable cutting tools please contact us.

Thorne & Derrick are Specialist Distributors of cable tools to enable the preparation of all LV MV HV cables prior to the installation of Joints, Terminations & Connectors – this includes Klauke, Cembre, Alroc and Boddingtons cable jointing tools for removal of cable sheath, screen and insulation on 11/33kV (MV) and 66kV/132kV (HV) power cables.

View the complete range of Cable Crimping & Cable Cutting Tools

Klauke Orange Insulated Tools | Innovation That Ensures Safety

Klauke Orange Tools

Klauke Orange

Cable Cutting & Crimping Insulated Tools 

Launched at ENERGYx2020 the KLAUKE Orange range of fully insulated tools manufactured by Klauke has set the standard within the global utility industry. Offering increased safety this range is the world’s first battery operated cable cutting and crimping tools with Tri-Insulation Barrier technology.

The orange housing of the battery powered cable crimping tool makes it easily differentiated from standard crimping tools and the built-in display allows user to view all tool data instantly.

Health & Safety is a main pillar of Energy Network Events and the KLAUKE Orange range is a huge leap forward in the development of battery-powered cabling tools for the cutting and crimping of overhead lines and underground cables.

You can find out more about ENERGYx2022 here: ➡ ENERGYx2022

You can view the complete range of KLAUKE Orange tools here ➡ insulated cable crimping and cutting tools.

Cable Cutting & Crimping

Insulated Tools & Total Safety

The world‘s first battery hydraulic crimping and
cutting tools with Tri-Insulation Barrier technology that provides users with 1.000V protection against
electrical shocks.

There have been several recent advances in cable cutting and crimping tool technology including data recording, bluetooth remote controls and pressure sensors.

All tools have become more compact making them more efficient for jointing and terminating cables in confined spaces as well as enhancing safety features.

Training, supervision, testing and PPE are all standards but what the KLAUKE Orange implements is another layer of electrical safety into the process.

➡ Download Brochure Klauke Cutting & Crimping Tools

• You frequently work in close proximity of live lines and parts. You cannot take any chances.
• You have ergonomic issues due to use of manual insulated tools. You want to work safe but with faster and more ergonomic tools.
• Cables you perceive as not live, can turn out to be live. You want to be protected at all times.
• Live line cutting is one of your safety critical tasks. You have to use safer tools for more protection.

The Klauke Orange battery hydraulic Cutting- and Crimp Tools are VDE Approved in accordance to IEC 60900 and fully VDE Certified to IEC 62841-1. See the full Klauke Orange range in the video below.

Tri Insulated Barriers on Klauke Tools

During the interview below, Paul stresses the importance of safe working practices including the physical aspect of the tool e.g. the body insulation of the cable crimping or cutting tool. The new Orange Line Tool uses a 3 level or tri-insulation system – the 3 level includes creepage distance, insulation material and oil within the system.

Klauke EKM 60/22 ID ISM VDE battery powered hydraulic crimping tool 6 – 300 mm²	Klauke EKM 60 ID ISM VDE battery- powered hydraulic crimping tool 10 – 240 mm²
Klauke ES 20 ISM VDE battery-powered hydraulic cutting tool 20 mm dia.	Klauke ES 32 ISM VDE battery-powered hydraulic cutting tool 32 mm dia.
Klauke ES 25 ISM VDE battery powered hydraulic cutting tool 25 mm dia.	Klauke ESM 35 ISM VDE battery powered hydraulic cutting tool 35 mm dia.
Klauke ESM 50 ISM VDE battery powered hydraulic cutting tool 50 mm dia (copper + aluminium cables)

Energyxtra Interview

Paul Morrow describes how Klauke was started in 1879 by two brothers in Germany originally making high quality pliers for the watch-making industry employing only 5 people. In 1960 when electrification become more popular Klauke shifted to developing cable lugs.

In 2018 they were acquired by Emerson and along with Greenlee and Rigid, Klauke can now service all the mechanical, electrical and plumbing requirements in the market.

For even more safety, Klauke has now developed the world‘s first battery hydraulic crimping and cutting tools with Tri-Insulation Barrier.

Before exhibiting at ENERGYx2020 Paul Morrow, UK & Ireland Manager from Klauke, part of the Emerson Group took part in an informative interview with Paul from Energy Network Events discussing electrical safety and the recent launch of the KLAUKE Orange range of fully insulated tools that have set the standard within the global utility industry.

Paul Morrow

Thorne & Derrick Testimonial

“Since 1985, Thorne & Derrick have gained a solid reputation for contributing to improvements in Workplace Electrical Safety throughout the industry – this includes assisting the launch of product innovations into the market, such as the Greenlee LS50 & Klauke VDE Orange and being a “go-to” supplier of electrical safety equipment to power industry contractors working with underground cables or overhead lines.

Increasing sales of our Strut Channel Cutter are an excellent example of a success story – the RIDGID STRUTSLAYR is recognised as the strongest and safest strut channel cutter on the market and is available from Thorne & Derrick stocks.

The sales and marketing staff at Thorne & Derrick worked hard and smart on introducing the STRUTSLAYR product to their clients and marketplace during COVID and are now seeing the impressive sales results.

Together during 2022 we welcome the opportunity to jointly promote more Workplace Electrical Safety improvements to be delivered through product innovations including the first remote-controlled cable cutters. For example, the Klauke ESG105RMCCFM and ESG65RMCCFM battery-powered, hydraulic cutting tools which will allow the user to maintain a safe distance whilst cutting cables,” comments Paul.

ENERGYx2022

Energy Network Events exists to safely promote and further the interests of everyone working in and supplying the electricity industry. The management team have years of experience working in industry, organising and promoting events and use their experience and contacts to win the support of Legislators, Regulators, Senior Managers, World Class Suppliers and Inspirational Figures.

VISIT

ENERGYx2022 Visitor Delegate FREE Tickets

EXHIBIT

ENERGYx2022 South Exhibitor Booking Form

ENERGYx2022 is the industry-leading Exhibition & Conference for anyone working within the Electricity Industry

LV, MV & HV Jointing, Earthing, Substation & Electrical Eqpt

Thorne & Derrick International are specialist distributors of LV, MV & HV Cable Installation, Jointing, Duct Sealing, Substation & Electrical Equipment – servicing UK and global businesses involved in cable installations, cable jointing, substation, overhead line and electrical construction at LV, 11kV, 33kV and EHV.

THORNE & DERRICK 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 HV 

Thorne & Derrick | Stockists & Suppliers | Joints Terminations Connectors up to 66kV