Technical report

Guideline for the

professional processing of
electrical connectors
Index

Which cable lug suits which application? 3

Tubular cable lugs for special applications 9

Indent crimping: Well-tried yet reliable? 15

Which method is correct? Crimp types at a glance 21

Hexagonal crimps for aluminium and copper 27

Best Practise for Installation
Aluminium compression cable lugs and connectors according to DIN 35

Accurately connecting copper and aluminium 41

Employee health: Less physical effort thanks to electrically-driven tools 47

2
 • Compression cable lugs according to
DIN 46235 for compression of solid, stran-
ded, fine stranded and finest stranded
copper conductors
• Copper tube cable lugs “standard design”
made from electrolytic copper (EN 13600)
• Compression cable lugs DIN 46235 ter-
minals not for solid conductors
• The selection of the correct cable lug
very much depends on the cable type
• The International Standard IEC 1238
part 1 applies to electrical and mechanical
properties of cable lugs

Which cable lug suits

which application?

3
Which cable lug suits
which application?
Small component with a great impact: A
poor cable connection can result in an
increased joint resistance and even in
fire. We will show you the correct pro-
cedure.
On the German market hundreds of different
versions of cable lugs are available. For the
electrician it is very difficult to choose from
this broad range the correct cable lug for
each specific application.
The following article gives an overview of
the different types of cable lugs for copper
conductors and details the facts which will
guarantee a safe and longlasting connection.
In principle we differentiate between three
types of cable lugs:
• Compression cable lugs according to
DIN 46235
• Standard tubular cable lugs
• Sheet metal terminals according to
DIN 46234.
Three types of cable
lugs: DIN compression
cable lugs, standard
tubular cable lugs
and sheet metal
terminals (from left
to right)
Compression cable lugs according to
DIN 46235
DIN standard 46235 defines the applica-
tion, dimensions and marking of cable lugs.
This standard allows use of these cable
lugs for compression of solid, stranded,
fine stranded and finest stranded copper
conductors. The Utilities market for in-
stance offer a wide range of applications.
4
Incorrect tools or an unprofessional crimp can
cause increased temperatures or even fire.
Markings on the product provide the installer
with essential information relating to the origin
and application of the DIN 46235 cable
lugs, which also applies for standard tubular
cable lugs.
Marking “KL 22 12 – 150” shows:
• KL: indicates manufacturer (in this
case Klauke)
• 22: Die code (only for compression
cable lugs DIN 46235)
• 12: Metric bolt size for connecting
bolt: size M12
• 150: Cross section of conductor in
mm2
In addition, these cable lugs indicate
the number of required crimps. For in-
stalling, the DIN standard recommends
crimping dies according to DIN 48083,
part1, 3 and 4 for solid, stranded and fine
stranded conductors. For braided ropes
the standard refers to the information
of the manufacturer.
Only DIN compression
cable lugs show the
required number of
crimps stipulated by
the manufacturer.
 Klauke generally recommends the use of he- tool is used. Incorrect tools or an unpro-
xagon crimping dies according to DIN 48083, fessional crimp can result in increased joint
part 4 for installing of compression cable lugs resistance, increased temperatures and
DIN 46235. Range of cross section is from even fire.
6 mm2 up to 1000 mm2, bolt sizes range
from 5 mm up to 20 mm. Electrolytic copper
according to EN 13600 is mandatory. Incorrect and correct
For corrosion protection, compression crimps in comparison:
An incorrect crimp
cable lugs – also standard tubular cable (above:excess crim-
ping, middle: low
lugs and terminals – are tin plated. force crimping, and
usage of incorrect
crimping tools can
result in an increase
in joint resistance
Copper tube cable lugs “standard design” and may jeopardise
Apart from DIN cable lugs, many manu- the installation; below:
correct crimping)
facturers also offer standard tubular cable
lugs, also made from electrolytic copper
according to EN 13600. As far as sizes
are concerned, standard tubular cable lugs
are mostly shorter than DIN cable lugs and
also differ in tube dimensions.

DIN compression
cable lugs are longer
than standard
tubular cable lugs

To exclude such consequences Klauke re-

commends for crimping of their cable lugs the
exclusive use of their appropriate crimping
Standard tubular
cable lugs (left) tools.
have different tube
dimensions than DIN
compression cable
lugs (right)
Sheet metal terminals according to
DIN 46234
Also for the sheet metal terminals certain
However, since these lugs are also subject standards apply regarding application,
to test standard IEC 1238 part 1, durability dimensions and marking.
of electrical and mechanical connection is Other than compression cable lugs DIN 46235
not affected. terminals are designed only for crimping
All cable lugs – irrespective of type – can of stranded, fine and very fine stranded
only be crimped properly when a suitable conductors – not for solid conductors.
5
Which cable lug suits
which application?
Cross section ranges from 0.5 mm2 up to
240 mm2, bolt sizes from 2 mm to 16 mm.
Among others terminals they can be found
in electrical control cabinets and vehicles of
public transportation services.
Sheet metal terminals are also made from
electrolytic copper according to EN 13600.
But there is a difference in the basic material.
While compression standard tubular cable
lugs are produced from copper tubes,
terminals are made from copper sheets.
Terminals show a soldered seam as the DIN
standard prescribes a closed tube.
The DIN standard does not specify crimping
tools – Klauke recommends their self-desi-
gned indent crimping tools.
Useful information
The selection of the correct cable lug very
much depends on the cable type.
For cables according to DIN 57295 the
following cable lugs can be used:
• Cables class 1, 2, 5 and 6:
Compression cable lugs DIN 46235
• Cables class 2:
Standard tubular cable lugs
• Cables class 2, 5 and 6: Terminals
In practice it can happen that flexible class
5 and 6 cable conductors do not fit into the
appropriate cable lug.
For such cases Klauke recommends the so
called F-cable lugs which have a larger inner
diameter and feature a flared entry. Indent
crimping is recommended.
For installing the DIN cable lugs, crimping
tools with die codes according to DIN
48083 part 4 have to be used.
6
F-Cable lugs with
flared entry represent
an option when
cables of class 5
and 6 will not fit into
normal cable lugs.
For tubular cable lugs please refer to the
tool recommendations of the manufacturer.
Electrical and mechanical properties
The International Standard IEC 1238 part
1 applies to electrical and mechanical pro-
perties of cable lugs. The requirments for
a permanent and safe electrical connection
for the intended application are detailed in
this standard. Both a mechanical pullout
test and an electrical durability test are de-
fined. A test cycle simulates the application
in practice: The connection is being heated
1000 times up to 120° C, to imitate the
morning voltage peak in the public power
supply system.
Also high current tests are being carried out
at temperatures of 250° C.
The responsibility of adherence to these
safety rules lies with every manufacturer of
cable lugs. For this reason the manufactu-
rers specify the appropriate cable type to
be used with their cable lugs.
Apart from normative standards, renowned
manufacturers stipulate additional quality
requirements. Klauke made cable lugs
are subject to an “annealing” process to
condition the material from tension and
hardness and to reduce the risk of fracture.
This process increases the durability and
provides greater protection for the lug
against vibration. This is another reason
why we only recommend use of high-quality
cable lugs from well known manu-facturers.

The longer tube of

Klauke cable lugs
(above) guarantees
a high quality con-
nection.

The quality of cable lugs can often be reco-

gnized by visual characteristics. A burr free
lug, a flat palm and a cleanly machined end
are signs of a high quality product.

High quality Klauke

cable lugs (above)
show a clean and
vertical tune end

Preview:
Cable lugs for special applications
Cable lugs per this article comply with
nearly all standard requirements of day-to-
day practice.
A great number of applications, however, for
instance solid conductors or connections
in switch cabinets require special cable lugs.

7
8
 • The above mentioned problem of spliced
cables per class 5 and 6 acc. to DIN 57295
is being avoided when using “F” type
series cable lugs.
• The tube diameter is matched to the con-
ductor size to guarantee a professional
crimp
• Cable lugs for switch cabinets with special
narrow palm cable lugs
• Especially for adverse environments and
for crimping copper conductors stain-
less steel and nickel tubular cable lugs
have been designed

Tubular cable lugs

for special applications

9
Tubular cable lugs
for special applications

This problem is known to every electrician:

When trying to insert a stranded or fine
stranded conductor into the cable lug
the cable splices and some wires cannot
be inserted. To avoid this problem re-
nowned manufacturers offer “cable lugs
for special applications”.
With these special cable lugs all types of cables
can be used. The design and construction is
geared to the characteristics of cable types
as classified in the DIN standard 57295.
Picture 1 shows the different types:
• Round single / solid conductors (re)
per class 1
• Round multi-stranded conductors (rm)
per class 2
• Fine stranded conductors per class 5
• Finestranded conductors per class 6.
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 con-
ductor fits into the cable lug.
Cable lugs “F type”
for fine stranded
conductors for easy
insertion with no
splicing

Conductor types acc.

to DIN VDE 57295:
round solid,
round stranded, fine
stranded, compacted
F-cable lugs for fine and very fine stranded
conductors
The above mentioned problem of spliced
cables per class 5 and 6 acc. to DIN 57295
is being avoided when using “F” type series
cable lugs. These lugs are designed for pro-
cessing larger cross sections in switch cabinet
construction, electroplating factories or in rail
vehicles. 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 entry.
10
This is also a safety-related issue:
A reduction of the cross section 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” and
shows
• KL: Manufacturer (Klauke)
• 12: Metric bolt size for connecting
bolt: size M12
• 150: Cross section of conductor in mm2
• F: Tubular
For professional crimping of F-type ca- As corrosion protection they are tin plated.
ble lugs the indent or quad point crimping Cross sections range between 10 mm2 up
method is recommended with the appropri- to 300 mm2. In addition to the normal design
ate tools and the correct indent profile. “F-type” cable lugs are also available as 45°
resp. 90° angled versions as well as inspection
holes to check whether the conductor is
F-type cable lug fully inserted.
shows professional
indent crimp
As with all other connections these pro-
ducts are subject to test standard IEC
1238 part 1, which guarantees a safe elec-
trical and mechanical connection has been
achieved. Cable lugs manufactured by
A cross sectional
view of an indent Klauke are subject to a special annealing
crimp (with manufac-
turers recommended
process to help relieve material stresses
tool) shows the even and hardness. This reduces the chance of
arrangement of
conductor in the lug material fracture and is an additional safety
feature.

To avoid over or under compression the
correct tooling is a prerequisite. An incorrect
crimping connection can result in increased
joint resistance leading to an increase in
temperatures and in the worst case in fire.
The quality of cable lugs can often be reco-
gnized by visual characteristics.
A burr free lug, a flat palm and a cleanly
machined end are indicative of a high quality
product.

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 extension and repair of
conductors. These 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 manu-
factured from electrolytic copper.
11
Tubular cable lugs
for special applications

Cable lugs for solid conductors (re) Cable lugs for switch cabinets
For processing solid conductors (class 1 acc. In many cases working area in switch cabi-
to DIN VDE 57295) the use of tubular cable nets is very tight and connecting conductors
lugs “E” type is recommended which are also to high-power switchgears can be a problem.
manufactured from electrolytic tin plated In case of larger cross sections standard
copper. cable lugs do not fit the connecting
Their tube diameter is matched terminal.
to the conductor size to guarantee a pro-
fessional crimp.
Special cable lugs
for switch cabinets
(type SG) for safe
connection also of
Professional crimp conductors
on a solid conductor
with matched tube
dimension

For such applications many manufacturers

have designed special narrow palm cable
Application is in all areas where solid con- lugs (SG cable lugs) which fit easily.
ductors are being mostly used, e.g. manu-
facutre of transformers and engines.
Direct comparison of
standard cable lugs
A hexagonal resp. indent crimping is being (left) and cable lugs
with narrow palm for
recommended. Again it has to be obser- switch cabinets
ved that both cable lugs and crimping tools
come from the same manufacturer.

Cable lugs for solid conductors can be re-

cognized by their smaller tube diameter and
the marking “E”. For example: KL 10 50 E.
Cross sections usually range from 6 mm2 up
to 50 mm2. The range is being completed
by butt-, T- and cross connectors having
the appropriate internal tube diameters.

12

Professional crimp on stainless steel cable
lug for application in ambient temperatures
of up to 400°
Shows the thicker
palm of SG cable
lugs for switch
cabinets, using the
same amount of
copper as used in a
standard cable lug.
Important is that this narrow palm is also thicker
than standard lugs insuring the same 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.
Cross sections range from 35 mm2 up to
300 mm2. The hole dimensions comply with
industry sizes of connecting terminals, e.g.
6, 8, 10, 12 and 16 mm.
Versions with inspection hole 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.
Stainless steel cable lugs for aggressive
environments
Especially for adverse environments and for
crimping copper conductors stainless steel
and nickel tubular cable lugs have been de-
signed.
Stainless steel cable lugs are particularly
acid and corrosion resistant and are typi-
cally used in chemical industries, in areas
exposed to sea water i.e. the earthing of
masts on sailing yachts.
An additional benefit of these 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
13
Tubular cable lugs
for special applications

Cross section ranges from 0.5 mm2 up

to 95 mm2. Generally an indent crimp is
recommended. The same applies for stainless
steel and nickel butt connectors with barrier.

Outlook:
AL and AL-CU Compression lugs
Another special situation is brought about
by the compression of Al and Al-CU cable
lugs for use with Aluminium conductors
Due to price and weight benefits a general
trend towards these can be seen.
To crimp these however a number of things
need to be observed.

14
 • W-crimp and indent crimp for different
cross-sections
• The permitted cable spectrum for indent
crimping comprises both class 2 multi-
stranded copper conductors, as well as
class 5 and 6 fine and ultrafine-stranded
types in accordance with VDE0295 up to
a cross-section of 400 mm2
• F cable lugs for ultrafine- and finestranded
conductors avoid the problem of fraying
• Practical crimping method for small
crosssections below 6 mm2 in any case,
and also in switch cabinet construction
up to 1 000 V

Indent crimping:
Well-tried yet reliable?

15
Indent crimping:
Well-tried yet reliable?

Benefits and limitations: The oldest form The greater impact forces, however, cause
of electrical connection, indent crim- high material stress. So it‘s important to re-
ping has proven its worth in countless member that connections caused by indent
applications. Yet for some time now, crimping are always strainrelieved.
experts have been repeatedly asking
the question: Is indent crimping still even
Indent crimping
reliable? allows multistranded,
fine-stranded and
ultrafine-stranded
Why this uncertainty: Today, hexagonal con ductors to be
permanently con-
crimping is considered to be the technical nected
standard that has generally become esta-
blished. But: Indent crimping is considered
to be an acceptable and a reliable form of
crimping that is preferred for switch cabinets The variants: W-crimp and indent crimp
of up to 1000 V. There are two different versions of indent
crimping in use:
• the W-crimp for cross-sections from
Indent crimping is
still a reliable form of
0.5 mm2 to 16 mm2
crimping, often used • the indent crimp for cross-sections
in the construction of
switch cabinets up to from 6 mm2 to 400 mm2
1 000 V

The W-crimp is ideal

for smaller cross-
sections, since the
material in the region
Indent crimping is a purely manufacturer- of the two tips of
specific kind of crimping. In other words: the crimp insert is
extremely highly
The manufacturer must ensure that a stan- compacted
dardised crimp can be produced using its
components. Leading manufacturers de-
Indent crimping is
monstrate this through appropriate tests. especially suitable for
cross-sections from
6 mm2 to 400 mm2
In tests to IEC 61238, for example, Klauke
proved its crimping tools and cable lugs
combined can be used to make connections
of equivalent quality to a hexagonal crimp.
Warning: unlike hexagonal crimping, indent The W-crimp is preferred for smaller cross-
crimping is suitable only for processing sections, since the material in the region of
copper. the two tips of the crimp insert is extremely
highly compacted.
In terms of technology, indent crimping is Indent crimping is commonplace and ge-
set apart by its high degree of compaction. nerally accepted for processing small
16
cross-sections, since the hexagon crimp is In contrast to the hexagon crimp, thinned con-
normally used only from cross-sections up- ductors can also be reliably crimped without
wards of 6 mm2. transmission losses by means of indent
crimping.

For multi-stranded, fine-stranded and
ultrafinestranded copper conductors
The permitted cable spectrum for indent
crimping comprises both class 2 multi-
stranded copper conductors, as well as
class 5 and 6 fine and ultrafine-stranded
types in accordance with VDE0295 up to a
crosssection of 400 mm2.
The reason: Thinned cables have in reality
a smaller cross-section than is nominally
specified – a specified cross-section of
50 mm2 can in actual fact only be around
43 mm2, for example. Thinned lines are
produced from high-purity copper. Despite
its smaller cross-section, this material has
identical conductivity characteristics.

The benefit to the manufacturer is the re-

• class 1 round duced material usage and the associated
single-stranded (rs) lower costs. One of the key advantages
conductor (com-
monly known as of indent crimping is this versatility in the
»solid conductor«)
• class 2 round wide range of the conductor types to be
multi-stranded (rm) processed. What’s more, all these conductor
conductor
• class 5 fi ne-stranded types can be indented simply and cost-
conductor 5 (com-
monly known as effectively using one tool. Klauke offers a
»flexible conductor«) mechanical crimping tool for indent crimp
• class 6 ultrafi
ne-stranded that covers a crosssection range of 185 mm2
conductor 6
(commonly known to 400 mm2, for example.
as »highly-flexible
conductor«)

The Klauke mechani-

cal crimping tool K07
for indent crimps
The various conduc- covers a cross-
tor types at a glance section from 185 mm2
to 400 mm2

Generally speaking, only mechanical hand

crimping pliers are used for indent crimping.
The crimping profiles to be used are based
on the tube dimensions of cable lug and
connector. But because indent crimping is
not a standardised form of crimping, it is
crucial that high-quality materials and tools
17
Indent crimping:
Well-tried yet reliable?
tested to IEC61238 from the same manu-
facturer are used.
A professional indent is obtained only from
clean workmanship using a suitable tool and
matching cable lug. That means: The tool
must be correctly applied and the indent
made up to the end stop of the tool. The
same number of indents as for a hexagonal
crimp is required. For example: A profes-
sional hexagonal crimp of a tubular cable
lug with a cross-section of 240 mm2 calls
for four narrow crimps; an indent likewise
requires four crimps.
Just like a hexagonal
crimp, the indent
crimp for a cable lug
with 240 mm2 cross-
section also requires
four narrow crimps
With indent crimping too, the cross-section
is stamped on the back of the crimp for che-
cking. Important in all cases: To avoid under
or over crimping, the use of a suitable and
well-maintained tool is a basic pre-requisite.
Incorrectly made crimps, due to an incorrect
tool setting for example, can increase contact
resistance which can in turn cause tempe-
rature rises and ultimately cable fires.
Indents made
incorrectly due to
unsuitable crimping
tools, for example,
can in the worst case
cause a cable fire
18
Klauke, for example, therefore recommends
that its cable lugs are crimped using only
its tools. This is the only way the electrical
engineer is guaranteed the use of matched
cable lugs or connectors and tools, which
are the prerequisite for a reliable connection.
Also important in this regard: F or R cable
lugs (Cu standard version) can be used for
indent crimping.
F and R-series cable
lugs can be used for
indent crimping
Focus: F and r series cable lugs
Thanks to their design, F cable lugs for fine-
stranded and ultrafine-stranded conductors
avoid the problem of fraying as they are intro-
duced into the cable lug. These tubular cable
lugs have a larger internal tube diameter than
»standard« cable lugs. They also have funnel-
shaped widening to better guarantee cable entry.
F cable lugs have
a larger tubular
inside diameter than
»standard« cable
lugs; they also have
a funnel-shaped
widening
Besides easier handling, this also brings
advantages in terms of safety: Cross-section
tapering due to fraying is prevented, and so
the cable retains its full cross section.
The funnel-shaped
widening of the F
cable lugs prevents
a cross-sectional
tapering of the cable
caused by fraying
Suitable for use with »F« series tubular
cable lugs, various manufacturers also offer
joints for conductor extensions or repair
purposes. These also have funnel-shaped
widening and an enlarged tube diameter.
A central impression prevents the two cable
ends being inserted unevenly.
Conclusion and outlook
Indent crimping remains a standardised
and practical crimping method. For small
crosssections below 6 mm2 in any case,
and also in switch cabinet construction up
to 1 000 V. If the recommendations given
in this article are followed, any uncertainties
about their reliability are unfounded. There
is no doubt, however, that the acceptance
of indent crimping among experts isn‘t
quite what it once was.
It is therefore important to clarify with cus-
tomers in advance as to whether they allow
indent crimping in their technical facilities
and plants. The arbor and 4-arbor crimp offer
a similar degree of compaction to indent
crimping. These crimps even allow the pro-
duction of gas-tight crimped connections.
We will be explaining what is important to
note about these types of crimp in a later
issue.

Tubular cable lug: Commercially available

»standard design«
In addition to DIN cable lugs, various manu-
facturers offer standard R-series tubular cable
lugs. Due to their dimensions, these tubular
cable lugs differ from DIN cable lugs – they
are usually shorter than the DIN designs.
But because they are governed by the same
test standard, this does not affect the durability
of the electrical and mechanical connection.

The standard R series

tubular cable lugs,
which are shorter
than DIN cable lugs,
guarantee a durable
connection when
indent crimping is
carried out correctly

19
20
 • The hexagonal crimp: The most common
type of crimp for cable lugs and connectors
• Indent crimps represent the oldest elec-
trical crimp profile
• The intensive indent crimp is guaranteed a
permanent and „deep acting“ connection
will be achieved
• Quad point crimps: The advantage is the
way the centric force is applied and that
no crimping dies are needed
• Gastight oval crimps are being used pre-
dominantly in aggressive environments

Which method is correct?

Crimp types at a glance

21
Which method is correct?
Crimp types at a glance
Initially the subject covering crimping
profiles seems complicated; the electrical
installer is confronted with a number
of different cable types, each requiring
different cable lugs or connectors and a
professional crimping method.
This combination depending on material,
design and application requires the correct
crimping profile to be used.
The following article will give a review of the
most common crimp profiles the electrician
should be familiar with (Review: see chart).
For copper and aluminium:
Hexagonal crimps
The most common type of crimp for cable
lugs and connectors is the hexagonal crimp
as this crimp profile is suitable for copper
and aluminium conductors.
A hexagonal crimp
is suitable for both
copper and alumi-
nium conductors.
The advantage is the
central force which is
applied consistently
from all directions.
The range of applications covering hexa-
gonal crimps includes the crimping of con-
ductors as per VDE-0295-categories 2, 5
and 6 and the processing of non-tension
connections of aluminium cables per DIN
48201 part 1, and aluminium ropes per DIN
EN 50182.
The advantage of a hexagonal crimp is the
central force which is applied consistently
from all directions and over a larger area
during the crimping operation. During this
22
CRIMPING PROFILES
Crimping Hexagonal- Indent Indent crimping Quad-point Oval-
solderless indent
profiles crimping crimping terminals crimping crimping
Symbol
Chart: Crimping profiles at a glance
crimping operation the individual strands of
the conductor are being homogeneously
compressed preventing any damage.
The result is a strong mechanical connection.
Due to the even compression the hexagonal
crimps are also suitable for application in
medium and high voltage areas.
However, these advantages are faced with
some limitations.
The complete compression of wire strands
using a hexagonal crimp and standard
crimping dies is not possible. This means:
Standard hexagonal crimps are not gas-
tight (see gas-tight oval crimps at the end of
this article). Therefore it should be observed
that a professional hexagonal crimp requi-
res the use of crimping dies which are mat-
ched exactly with material and dimensions.
Hexagonal Crimps – DIN Type
Hexagonal crimps differ in two versions:
One relates to the standard hexagonal
crimp in accordance with DIN 48083 part 4
and the other to the manufacturers related
hexagonal crimp. The standardized hexa-
gonal crimp allows cable lugs and connec-
tors according to DIN 46235 to be crimped
with certified crimping dies per DIN 48083
part 4.

The standardized
hexagonal crimp
allows cable lugs and
connectors per DIN
46235 to be crimped
with certified crimping
dies per DIN 48083
part 4.
Marking on DIN cable lugs provide es-
sential information as to manufacturer,
dimensions and design of the cable lug.
These markings indicate for instance
which crimping tools and crimping dies
need to be used to achieve a DIN compliant
crimp. This designation is next to the
manufacturers’ marking.
For instance “KL 18...” stands for KL:
manufacturer (in this case Klauke) and 18
for the die code. The correct die code is
a condition of a professional DIN crimp:
Crimping dies used in the crimping tool
need to comply with the die code shown
on the cable lug. The mirror image of the
die code can be seen on the surface of the
crimping dies. After the crimping operation
the die reference code can be seen on the
barrel of cable lug as part of a visible and
recordable quality control procedure.
The die code corresponds approximately to
the tube diameter of the cable lug. The range
of copper lugs is approximately from 6 to
58 which correspond with the cross sec-
tions from 6 mm2 to 1000 mm2. Hexagonal
crimping dies per DIN 48083 part 4 for alu-
minium lugs and connectors are described
in accordance with the tube dimensions of
lugs per DIN 46239 and connectors per
DIN 46267 part 2.
The alternative:
Manufacturer specific hexagonal crimps
Apart from DIN standard hexagonal crimps
the crimping of copper and particularly of
cable types per VDE 0295 classification
2 also allows for a manufacturer related
hexagonal crimp to be used.
Prestigious manufacturers such as Klauke
provide hexagonal crimping dies tested and
approved to IEC 1238 for crimping standard
copper cable lugs as per EN 13600. For
commercial reasons such cable lugs are
often used in control and switch cabinets.
Despite offering cost benefits, there is no
reduction in quality.
Important: The use of manufacturer related
crimping dies and cable lugs are not con-
trolled through the die codes. Instead it
depends more on the cross section of the
cable being used indicated in mm2, the
cable lug and the die reference. The square
mm size is mirror printed on the crimping
surface of the crimping dies.
Every manufacturer is responsible for the
electrical and mechanical durability of con-
nections crimped with there own tools. As
a safe and professional crimp is dependant
on accurately matching suitable crimping
dies to the cable lugs, Klauke always recom-
mends using the manufacturers approved
crimping tools.
23
Which method is correct?
Crimp types at a glance

Proven and tested: Indent crimps
The indent crimp represents the oldest
electrical crimp profile. This crimp profile is
solely suitable for the processing of copper
and is often used in control panels and
switch cabinets operated within a range
of 1000 V. The permissible cable range in-
cludes stranded conductors per VDE 0295
classification 2 and also fine stranded and
compacted conductors per classification 5
and 6 up to 400 mm2. These conductors can
be processed with R and F series tubular
cable lugs.
Generally two different types of indent
crimps are used: The W-profile for cross
sections from 0.5 mm2 up to 16 mm2 and
the classic single indent crimp for cross
sections from 6 mm2 up to 240 mm2.
Klauke crimping tools offer the possibility to
indent crimp cross sections up to 400 mm2.
The characteristics of both versions are
identical: Indent crimps are always special
crimping operations particularly required for
fine stranded and compacted conductors
to secure a permanent connection.
Indent (side indent) are
always special appli-
cation crimps which
are primarily used for
crimping fine stranded
and compacted con-
ductors to secure a
permanent connection.
The applied crimp
profiles depend on the
cross section of the conductor and type of cable lug.
cross section of cables, cable lugs and
connectors to be used.
Since the indent crimp does not repre-
sent a standardized crimp it is imperative
to only use high quality materials and tools
approved per IEC 1238 originating from
one manufacturer. Only in this case the
electrician is safeguarded utilizing cable
lugs, connectors and tools which are matched
to each other and which provide and gua-
rantee a safe connection.
For copper and insulated materials:
Indent crimps
Indent crimps have been specifically de-
veloped for processing connections of
cablelugs according to DIN 46234 and con-
nectors per DIN 46341 part 1, form A+B,
which in turn are suitable for conductors of
VDE 0295 classification 2, 5 and 6.
Cable lugs and connectors complying with
these standards feature a particular large
outside diameter which will accept all types
of cables without any problem. The intense
indent crimp ensures that despite of the
large outside diameter a long lasting and
“deep acting” crimp is achieved.

The real benefit of indent crimping is the

simple operation and procedure for which
normally hand operated crimping tools can
be used.
The applied crimp profile depends on the
24
 The intensive indent Cable lugs with a high
crimp is only guaran- quality insulation and
teed when matched appropriate crimp
materials are use profiles ensures that
despite the large the insulation does
outside diameters not become damaged
a permanent and during the crimping
„deep acting“ operation.
connection will be
achieved.

The indent and the side indent are also

• class 1 round
single-stranded (rs) non-standard types of crimp but can also
conductor (com-
monly known as
be used for standard cable lugs such as
»solid conductor«) terminals per DIN 46234. For this reason
• class 2 round
multi-stranded (rm) here it is also important to use tools and
conductor
• class 5 fi ne-stranded
materials from a single quality manufacturer.
conductor 5 (com- Materials incorrectly matched are disadvan-
monly known as
»flexible conductor«) taged further due to the extreme stresses
• class 6 ultrafi
ne-stranded
applied during use. Once a single strand
conductor 6 has been lost mechanical and electrical
(commonly known
as »highly-flexible failures in the connection may become
conductor«) inevitable.

The permitted cross sections range from
0.5 mm2 up to 240 mm2. An indent crimp is
also suitable for F-type cable lugs ranging
from 10 mm2 up to 300 mm2.
F-type cable lugs feature a larger diameter;
funnel shaped tube to accept fine stranded
and compacted types of cables per VDE 0295
classification 5 and 6 without any splitting.
An indent crimp is also suit-able to crimp
pre-insulated terminals in accordance with
DIN 46234 where the crimp pierces the
insulation. To avoid that the insulation is
damaged during the crimping operation it
is imperative to only use cable lugs with
a high quality insulation and appropriate
crimp profiles.
No dies required: Quad point crimps
The quad point crimp originates in the USA
and is being used mainly in panels and
switch cabinets up to 1000 V. These are
also used in other electrical connections i.e.
in drive systems for locomotives where this
type of crimp offers the perfect solution.
This crimp profile is suitable for cable lugs
and connectors ranging from 10 mm2 up
to 300 mm2 in combination with cables per
VDE 0295 classification 2, 5 and 6.
25
Which method is correct?
Crimp types at a glance

The quad point crimp Gastight oval crimps

is suitable for cable
lugs and connectors
with cross sections
ranging from 10 mm2
up to 300 mm2 in
combination with
cable types per VDE
0295 classification 2,
5 and 6.
Attention: Application for use with pre-
insulated cable lugs and connectors is not
allowed.
The advantage over a simple indent crimp
is the way the centric force is applied and
that no crimping dies are needed.
This means that with just one crimping tool
all the above mentioned cross sections
can be processed. The quality of the crimp
depends solely on the force and quality of
the crimping tool used.
Gastight: Oval crimps
Gastight oval crimps are being used pre-
dominantly in the motor industry and in ag-
gressive environments such as agricultural
operations or chemical industries. A gas-
tight connection means that both conductor
and cable lug or connector is compacted
together so tightly that no notable gap
exists.
provide for a per-
manent connection
and good electrical
conductivity.
The ingress of fluid or
a gaseous medium
is not possible under
normal atmospheric
conditions.
An oxidation of the individual crimped strands is prevented and
an increase in resistance is avoided.
This means that the ingress of fluid or a ga-
seous medium is not possible under normal
atmospheric conditions.
An oxidation of the individual crimped
strands is prevented and an increase in re-
sistance is avoided. For this reason gastight
oval crimps provide for a permanent con-
nection and good electrical conductivity.
A gastight connection can be tested by in-
specting the polished cross section of the
lug. There is no restriction to specific types
of cables; therefore all types of conductors
are suitable for gastight oval crimps.
To meet the high technical requirements of
gastight connections it is absolutely impe-
rative to use only high quality branded crim-
ping tools and connecting material.
Outlook: Which crimp profile for the pro-
fessional solution?
To ensure that durable crimping connections
are achieved, specific crimping operations
are required.
In our next edition we will feature the various
crimp profiles in detail and will explain what
needs to be observed to obtain a professional
high quality connections.

26
 • Hexagonal crimping is suitable for both
copper and aluminium conductors
• A professional hexagonal crimp generally
requires use of crimping dies which match
sizes of conductors and connecting
material
• The classification of manufacturer specific
crimping dies and cable lugs is rather
regulated by the cross section of the cable
• The primary application of standardized
hexagonal crimps is with electric utilities
within a range from 10 kV up to 30 kV
• Depending on the tool narrow or wide
crimps can be used

Hexagonal crimps for

aluminium and copper

27
Hexagonal crimps for
aluminium and copper

In daily practice hexagonal crimping is

the most common kind of crimping of
cable lugs and connectors.
The reason is very simple – this type of
crimp is suitable for both copper and alu-
minium conductors. Hexagonal crimps
can be found in panel building industries
as a manufacturer specific crimp and
The cross section of
also as a DIN standard crimp for example a hexagonal crimp
in utilities (aluminium and copper). performed with a
manufacturer
recommended tool
shows the uniform
Technically the hexagonal crimp is charac- positioning of
terized by a centrical and constant force conductors in the
cable lug
effect applied during the crimping operation
from all sides and creating a larger contact
area. Apart from mechanical pull out tests also
electrical durability tests are included.

Hexagonal crimps
are suitable for both
The field of application of hexagonal crimps
copper (above) and comprises the processing of conductors as
for aluminium (below)
per VDE 0295 classification:
• Class 1: round solid conductors
• Class 2: round stranded conductors
• Class 5: round fine stranded conductors
• Class 6: round finest stranded con-
ductors

Conductors acc. to
DIN VDE 57295 Top
The individual strands of the conductors down: round solid
conductors, round
are being deformed homogeneously in their stranded conductors,
round fine stranded
entirety without any damage. conductors, round
finest stranded con-
ductors
The results are good electrical properties of
these connections. Mechanical and electri-
cal properties of tubular and DIN compres- In addition hexagonal crimps per DIN 46235
sion cable lugs are being defined by the resp. DIN 44267 can also be used for pro-
IEC 1238 part 1. It defines the requirements cessing of non-tension and full tension
that an electrical connection has to fulfil for connections of aluminium cables per DIN
a permanent safe operation within intended 48201 part 1 resp. of aluminium ropes per
applications. DIN EN 50182.
28
Important: The correct tool
For processing cable lugs per DIN 46235
Comparison of
crimping dies with die codes per DIN 48083 incorrect and correct
can be used. This combination enables crimps: Faulty crimps
(above and middle)
he xa gonal crimps per DIN 46235 and or the use of incorrect
crimping tools can
46267. For hexagonal crimps of standard lead to increased
tubular cable lugs it is sug - gested to strictly contact resistance
and consequently
observe manufac - turers tool recommen- can endanger the
safety of the equip-
dations. ment resp. facility);
below = correct crimp

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. Back ground: An incorrect combination can lead to low
A totally completed crimp is important as compression resp. excess compression
the required compression of the crimp ma- crimps with po tentially fatal consequences:
terial is only reached at the end of the crimp Faulty crimps can lead to increased contact
phase. resistance with rise of temperatures which
in the worst case can cause fire.

Preparation of a professional crimp

A professional hexagonal crimp generally re-
quires use of crimping dies which match sizes
of conductors and connecting material.
That means that cable lugs resp. connectors
need to correspond to the dimensions of
the conductor and crimping die.

29
Hexagonal crimps for
aluminium and copper

While stripping conductors it has to be ob-

served that same are not being damaged
Incorrect or materials
pro - cessed with in- and that bared length is more or less iden-
appropriate tools can
cause heavy defects
tical with insertion length of cable lug resp.
on installations resp. connector. Crimping dies need to be clean
electrical equipment
and metallic bright.

To avoid the incorrect die selection Klauke

Cable lugs of poor differentiates in colour, silver stands for
quality and/or pro-
cessing may cause
aluminium dies and yellow gold for copper
fire dies.

Left: crimping die

for aluminium, silver
coloured;
right: crimping die
For this reason manufacturers of branded for copper (yellow-
products such as Klauke recommend for gold colour)

crimping operations their cable lugs and

connectors solely use of their own appro-
priate tools. High quality crimping dies can
be recognized by a polished surface with Tip: Klauke recommends to start crimping
rounded edges. operations on cable lugs always from the
palm towards the cable.
In this case the compressed material can
Example of a slide towards the cable end which hasn’t
crimping die with
polished profile been crimped.

A cable lug resp.

connector always
needs to be crimped
under consideration
These crimping dies are precisely manufac- of the crimping
direction and use of
tured and guarantee a constant and neat appropriate tools

deformation of copper resp. aluminium.

It goes without saying: Prior to the crimping

operation one has to make sure 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.
30
Manufacturer specific hexagonal crimps
For hexagonal crimping operations we dis-
tinguish between two versions:
• The hexagonal crimp as per DIN 48043
part 4
• The manufacturer specific hexagonal
crimp
Within the standard copper range the so
called manufacturer specific hexagonal
crimps are used for cable types as per VDE
0295 class 2.
Permissible:
The 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
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 pro-
perties.
To achieve an IEC approved connection it is
necessary that all components used match
each other.
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
mm2.
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 crim-
ping is dependent from an exact matching of
crimping dies and cable lugs Klauke recom-
mends 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 manu-fac-
turer of both tools and cable lugs.
Brand manufacturers will perform – if requi-
red – for the specific application pull out tests
(accelerated tests) as per IEC and where
applicable also tests of the electrical con-
tact resistance and recommend depending
on the results adequate tools and materials.
31
Hexagonal crimps for
aluminium and copper
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 com-
plied with in terms of safety.
Standardized hexagonal crimping
The primary application of standardized he-
xagonal 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 con - sistent 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 con-
ductive compound.
Mainly for electric
utilities:
DIN standardized
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 connec-
tors and cable lugs with appropriate tube
dimensions as well hexagonal crimping
dies as per DIN 48083 part 4 can be used.
32
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 manu-
facturer code. For instance KL18 stands for
• KL: manufacturers code (in this case
Klauke)
• 18: tool resp. die code
For a professional completion of a standar-
dized 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 Option: Wide or narrow crimps
the crimp surface of the crimping die and Depending on the tool narrow or wide crimps
once crimping operation has been completed can be used. On a cable lug of 50 mm2
it is visible on the cable lug. cross section for instance one has the alter-
native to do two narrow crimps or one wide
Crimp.
Tool code on the cable
lug and imprinted code
verify a correct crimp
Narrow crimp
(above)
and wide crimp
(below)

Tool codes correspond approx. with the

tube dimensions of the cable lugs. For cop-
per die codes range from 5 up to 58; this
corresponds to cross sections from 6 mm2
up to 1000 m2. In the same way hexagonal
crimping dies for aluminium and appropria-
te tube dimensions of these cable lugs and
connectors are standardized.
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 conse-
quently 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.

33
Hexagonal crimps for
aluminium and copper

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

Outlook: Indent crimps

Old, but proved and tested: Indent crimps
constitute the oldest type of crimping ope-
rations 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.

34
 • The hexagonal crimp: The most common
type of crimp for cable lugs and connectors
• Indent crimps represent the oldest elec-
trical crimp profile
• The intensive indent crimp is guaranteed a
permanent and „deep acting“ connection
will be achieved
• Quad point crimps: The advantage is the
way the centric force is applied and that
no crimping dies are needed
• Gastight oval crimps are being used pre-
dominantly in aggressive environments

Best Practise for Installation:

Aluminium compression cable lugs and connectors
according to DIN.

35
Best Practise for Installation:
Aluminium compression
cable lugs and connectors
according to DIN.

Material properties of aluminium cable

are very different from those of copper.
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 pro-
cedure has to be carefully observed.
The advantages of aluminium are increasin-
gly coming to the fore in power distribution
applications, due to the lower material
weight and the relatively simple handling.
Power utilities tend to install more and more
aluminium cables, for instance ring mains
for urban power supplies.
In principle it is recommended to use solely
high quality aluminium compression cable
lugs with tube dimensions acc. to DIN
46329 and aluminium connectors with tube
dimensions acc. to DIN 46267 part 2. Pro-
ducts of renowned manufacturers such as
Klauke are made from premium electrolytic
aluminium alloy.
The barrier design
with oil stop prevents
leakage of oil of the
paper insulated
conductor.
Installation of compression cable lugs and
connectors for aluminium conductors is very
different from installation of copper conduc-
tors. Failure of vital installation procedures
can lead to a severe lack of safety.
Special sized cross sections are available
up to 1000 mm2, for instance for subsea
cables with high transmission capacities.
Aluminium compression cable lugs feature
a barrier design. (acc. to DIN 46239) which
allows installation on oil impregnated, paper
insulated cables and consequently provides
a firm water/oil block.
Aluminium conductors at a glance
Aluminium conductors are available in four
different types which in some cases require
special installation procedures. These are:
• re = solid round conductors
• se = solid sector conductors
• rm = round stranded conductors
• sm = sector stranded conductors

These products feature a constant material

thickness, exact diameter and a correct fit
which ensures simple installation and abso-
lute safety.

Standard cross sections range from 10 mm2

up to 500 mm2.
36
 Different types of
aluminium conductors
These abbreviations can be found on alu-
minium 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 manu-
facturer, dimensions and type of product.
For example marking “KL 18 10-70 /rm/sm
95 re/se” denotes:
• KL: manufacturer (in this case Klauke)
• 18: die code
• 10: metric bolt size (bolt M 10)
• 70: nominal cross section of conductor
in mm2
• rm/sm: for round stranded and sector
stranded conductors
• 95: nominal cross section of conductor
in mm2
• re/se: for solid round conductors and solid
sector conductors
Markings on the
cable lugs indicate
manufacturer, bolt
size, cross section
and cable assignment.
Important: The nominal cross sections of
se and re conductors are always one cross
section size above the cross sections of
sm and rm conductors. This is due to solid
conductors having a smaller diameter than
their stranded equivalent.
Special attention should be given to the
die code: For a professional installation the
crimping dies of the appropriate tool must
be matched with the code of the cable lugs.
Die codes on crimping dies are mirror-in-
verted – after the crimping operation the die
code is clearly visible for quality control and
documentation.
37
Best Practise for Installation:
Aluminium compression
cable lugs and connectors
according to DIN.

The visible signs of a correctly

crimped lug are the same for copper con-
Imprint of die code
“18” on the cable lug nectors as they are for Aluminium:
(above) indicates the
crimping die used.
In order to achieve a professional instal-
Completed crimp lation – with no over or under crimping –
(below) with marking
“18” on the cable lug the use of the appropriate tool is essential. An
refers to the correct
crimping die.
incorrect installation can result in increased
joint resistance and even in fire.

To avoid such consequences Klauke re-

commends to use the same manufacturers
tool as the lug or connector. This ensures a
matched system.

For instance the specific dies for aluminium

For a professional installation hexagonal have a crimping ‘bite’ width of 7 mm, which
crimping dies (acc. to DIN 48083 part 4) are is 2 mm wider than for copper lugs and
recommended. connectors.

The contact surface

Over compression (bite width) of
(above) is the result of crimping dies for
a crimping die which aluminium cable lugs
is too small, whilst (left) are 2 mm wider
under compression than their copper
(middle) is caused by equivalent (right).
the use of a crimping
die which is too large.
The picture below
shows a correct crimp
using an appropriate
crimping die. The reason for this is that wider compression
areas result in better conductivity and
therefore compensate for the poorer elec-
trical 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.

38
Compound for Aluminium Connectors
Cable lugs and connectors for aluminium
are supplied with a special compound
within the barrel.
Compounds with ad-
ditives like corundum
generate a “grinding
effect”.
During crimping, this compound destroys
the non-conductive oxide layer on the alu-
minium in the crimping area, increases the
contact properties and ensures the correct
electrical connection. In addition the com-
pound prevents admission 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
dryingout and leaking.
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 conductor and sleeve,
which prevents jamming of materials and
helps to provide a clean contact surface.
When used on stranded conductors, the
compound is distributed between the in-
dividual wires during the crimping process
and seals them against oxygen and mois-
ture ingress.
It is also important to know that aluminium
crimp connections installed using com-
pound perform much better when sub-
jected 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.
39
Best Practise for Installation:
Aluminium compression
cable lugs and connectors
according to DIN.

Installation of aluminium compression ‘Narrow’ crimps (approx 7 mm) are perfor-

cable lugs and connectors med by tools of at least. Also the correct
In order to accommodate the special cha- crimping direction has to be observed – al-
racteristics of Aluminium material, the ways crimp in the direction of the conduc-
following five installation steps are essential: tor.
• Remove insulaltion of aluminium con-
ductor
• Clean the blank conductor ends with a
Start the first crimp
at the lug end and
wire brush to remove an oxid film and progress towards the
conductor to ensure
to provide a clean surface that compacted

• Insert the conductor into the cable lug

material expands in
this direction.
or connector to the recommended
length. Some compound will emerge
from the mouth of the cable lug or con-
nector which is now hermetically sealed Al/Cu Compression cable lugs
to prevent further oxidation of the con- A further important technical issue is the
ductor. correct method of connecting aluminium
• Start the hexagonal crimping operation and copper conductors.
with a suitable crimping tool.
Important: Sector shaped conductors
need to be pre-rounded with appropriate
crimping dies.
• Remove any excess compound emerging
from the lug or connector.

Please note:
All DIN compression cable lugs show mar-
kings on the outside of the barrel for the
correct crimp position, and consequently
number of crimps required.
This is dependant on if you are using narrow
or wide crimping dies.

Markings on the cable

lugs indicate number
and position of crimps
as per manufacturers
recommendation.

40
 • Copper and Aluminium conductors are
difficult to connect to each other
• Leading manufacturers of high quality
compression cable lugs for connecting
aluminium connectors with copper bus
bars
• Aluminium conductors are available in
four different versions which require in
some cases special processing
• Connecting compound for aluminium
connecting material improves the contact
properties
• Al/Cu Connectors for a correct connection
of aluminium and copper conductors

Accurately connecting
copper and aluminium

41
Accurately connecting
copper and aluminium
Copper due to its outstanding electrical
properties are always the first choice
when selecting a conductor for an elec-
trical connection.
A practicable alternative in many cases
is aluminium particularly because of its
low weight and easy application. In
practice however the electrician can find
it challenging to connect both these ma-
terials in a professional manner.
Acopper-aluminium connection is used for
instance in an industrial estate where local
business use copper supply cables which
are then fed off an aluminium ring main.
But also in electrical substations it is neces-
sary to connect aluminium conductors to
copper bus bars. The main problem here
is that connecting aluminium and copper is
not straightforward. To ensure a safe and
correct connection the use of special alu-
minium/ copper cable lugs and connectors
are essential.
Use of an incorrect
crimping die and/or
an incorrect crimp
will result in an over
compression (right)
or an under com-
pression (left) and in
the worst case in fire.
42
Aluminium-Copper:
A problematic connection
Generally aluminium is a reactive material
that oxidizes easily, but in practice it has
proved to offer good corrosion resistance.
This characteristic is due to a chemical
reaction that takes place when in contact
with atmospheric oxygen resulting in a very
thin but also very resistant oxide layer being
formed. (oxide barrier)
When metals are connected to those with a
higher electrical potential such as copper in
the presences of an electrolyte (condensed
water) will result in an electrochemical re-
action taking place. During this process the
differences caused in electrochemical po-
tential can have a significant impact.
An electrical circuit is generated by the
copper electrode (anode), the electrolyte
(water) and the aluminium electrode
(cathode). The voltage generated in this
copper and aluminium circuit “semi metallic”
state results in a short circuit.
As a result of the current generated the Alu-
minium surface breaks down causing the
metal to electrolytically decompose. This
destructive process is visible as a kind of
blooming oxidation and begins already with
the existence of tiny copper particles on
the aluminium; this ongoing reaction itself
does not cause the copper to corrode.
In an electrical connection however the re-
sistance is increased leading to increased
temperatures which then in the worst case
lead to a fire.
Therefore when connecting copper and
aluminium it is important to ensure that no
moisture can enter the connections.
In an environment where moisture is present
the contact points between the copper and
aluminium need to be protected by using
accurate operating procedures.
The construction
of Al/Cu cable lugs
prevents any gaps
which would allow
the accumulation of
liquid to take place
which would start the
oxidation process.
Primarily this requires the use of aluminium/
copper cable lugs and connectors.
Due to the design of these lugs areas where
moisture could accumulate and where the
oxidation process could start have been
avoided. For this reason aluminium/copper
cable lugs and connectors are specified for
the use in off-shore wind power stations.
Leading manufacturers of high quality com-
pression cable lugs for connecting alu-
minium connectors with copper bus bars
consist of an electrolytic aluminium (E-Al)
compression and are joined to a copper
palm (to EN 13600).
The available cross sections range from 16
mm2 up to 400 mm2.
The field of application covers in principle
all non-tension connections of aluminium
cables acc. to DIN 48201, part 1, and alu-
minium ropes acc. to DIN 50182.
Specifications and processing of alumini-
um/copper compression cable lugs are the
same as those for pure aluminium versions.
Quality products manufactured by market
leaders such as Klauke feature a consistent
material thickness, exact diameters and
correct fit are a prerequisite for ensuring
high safety standards are always met.

Like aluminium compression cable lugs con-

Aluminium/copper compression cable forming to DIN 46239, aluminium/copper
lugs compression cable lugs feature a barrier
Leading manufacturers of high quality com- design allowing the use of oil soaked and
pression cable lugs for connecting alu- paper insulated cables which prevents oil
minium connectors with copper bus bars leakage.
consist of an electrolytic aluminium (E-Al)
compression and are joined to a copper
palm (to EN 13600). Aluminium conductors at a glance
Aluminium conductors are available in four
different versions which require in some ca-
A professional ses special processing.
connection of an
aluminium conductor
with a copper busbar These are:
is done by means of
an aluminium cable • round solid conductor(re)
lug and a copper
• sector solid conductor(se)
palm.
• round stranded conductor (rm)
• sector stranded conductor (sm)

43
Accurately connecting
copper and aluminium

The die code also needs special conside-

ration. For an accurate and safe crimp the
Various shapes of
aluminium conductors die reference should be the same as that
shown on the cable lug. The die code can
be seen on the die face as a mirror image
so that after compression the die code is
visible on the cable lug for final control and
inspection.

For an accurate processing of Al/Cu com-

pression cable lugs it is generally recom-
mended to use hexagon crimping dies acc.
to DIN 48083 part 4. In order to ensure an
accurate and professional crimp avoiding
over or under compression is the use of ap-
These abbreviations will be found next to propriate crimping tools. Poor crimps can
other markings on all Al/Cu compression result in an increase in joint resistance and
cable lugs and identify which conductors temperatures that can lead to fires. To pre-
will suit the appropriate cable lug. vent such issues Klauke solely recommend
using the manufacturers crimping tools to
crimp their cable lugs.
The markings on the
cable lug provide
information relating For instance the special crimping dies for
to the crimps, the
manufacturer, cross aluminium have a crimp width of 7 mm, i.e.
section and alloca-
tion of cable.
2 mm wider than the crimping dies for copper
cable lugs and connectors. This, however,
only applies to 60 kN crimping dies.

Markings on the product provide the instal- The reason for this is that dies with a larger
ler with essential informations. Marking “16 crimp width are able to connect a wider
KL25 150 rm/sm 185 re/se” stands for conductor surface area with the cable lugs
• 16: Metric bolt size for connecting bolt and balance the poor conductivity of alumi-
– size M16. nium. To easily identify which die should be
• KL: Manufacturer (in this case Klauke) used, Klauke manufactures aluminium dies
• 25: Die code in a silver colour while dies for copper are
• 150: Cross section of conductor in mm2 yellow-gold coloured.
• rm/sm: for round multi-stranded and
sector stranded conductors
• 185: Cross section of conductor in mm2
• re/se: for round single stranded solid
and single sector solid conductors
44
Connecting compound for aluminium
connecting material
All cable lugs and connectors for aluminium
conductors come with a special compound.
High quality alu-
minium cable lugs
come with a special
compound which
improves the contact
properties and
ensures a perfect
electrical connection.
This aggravates the non-conductive oxide
layer which is quickly formed on the sur-
face. This compound improves the contact
properties and enables a perfect electrical
connection, and also prevents further oxygen
penetrating the contact joints where further
oxidation could take place. To maintain the
functional capability of the compound all
leading brand cable lugs are sealed with a
plastic plug to prevent the compound from
drying-out and leakage.
Al/Cu Connectors
For a correct connection of aluminium and
copper conductors leading manufacturers
such as Klauke offer reduction compression
joints with a cross section range from
10 mm2 up to 300 mm2.
These products serve mainly the reconst-
ruction of power lines, i.e. non-tension con-
nections of aluminium conductors acc. to
DIN EN 60228 resp. aluminium wires acc.
to DIN EN 50182 with copper cables acc. to
DIN 48201, part 1 and copper conductors
acc. to DIN EN 60228. These compression
joints consist of interconnected aluminium
(E-Al) and copper parts (acc. to EN 13600).
Normally the aluminium part of the cross
section has a much larger diameter to com-
pensate for the poor conductivity of alumi-
nium.
Normally the alumi-
nium section (right)
has a larger diameter
than the copper sec-
tion (left) to equalize
the poor conductivity
of aluminium.
As with the cable lugs here too plastic plugs
are used to prevent drying-out and leakage.
Important: The use of Al/Cu compression
joints requires that the correct processing
guidelines for copper and aluminium are
observed.

Aluminium and
copper conductors
with different cross
sections are being
connected using
reduction sleeves.

45
Accurately connecting
copper and aluminium

Consequently the aluminium section needs Advice: When using crimp connections in
to be crimped like an aluminium compressi- the ground it should be strictly observed
on cable lug (see picture on the right). that the connecting joints should be pro-
tected against moisture. For this application
Characteristically for Al/Cu compression Klauke recommends use of cast-resin
joints are the different crimping marks which joints.
are 7 mm on the aluminium section and 5 mm
on the copper part for crimping dies up to
When used in the
60 kN. ground cast-resin
The procedure for the copper section is ab- joints protect the
connections against
solutely identical as on copper compression moisture.
It is important to
cable lugs. consider that the
connection is not
subject to bending
The crimping marks on the product give to avoid the risk of
fracture.
detailed information as to origin and appli-
cation of the Al/Cu compression joints.
For the application of Al/Cu compression
The marking “KL14 50 rm/70 re/se” signifies joints and cable lugs the following should
• KL: Manufacturer (in this case Klauke) also be considered: These products should
• 14: Die code not be exposed to bending stresses which
• 50: Cross section of designed conduc- could fracture the contact point.
tor in mm2 Application on overhead lines is therefore
• rm/sm: for round stranded and sector excluded.
stranded conductors
• 70: cross section of solid conductor in
mm2
• re/se: for round solid and sector solid
conductors

The marks on the copper section also

indicate the correct procedure.
The standard suggests crimping dies acc.
to DIN 48083 part 1, 3 and 4 for solid-, fine
and fine stranded conductors; for braided
round wires the standard refers to specifi-
cations of the manufacturer.

Generally Klauke recommends using he-

xagon crimping dies acc. to DIN 48083
part 4 for processing the copper section
of their compression joints.
46
 • With a manual force of up to 20 kilo-
grams per crimp, excessive strain in the
wrist and forearm can occur over time
• There is a good case here for taking
measures to guard against such condi-
tions and prevent expensive employee
absences
• Electromechanical crimping tools reduce
the physical effort, achieve the best
crimping results and also guarantee the
consistently high quality
• For specialist operations in which large
numbers of connections have to be pro-
cessed quickly, purchasing such tools
makes perfect sense

Employee health:
Less physical effort thanks to electrically-driven tools

47
Employee health:
Less physical effort thanks
to electrically-driven 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.
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 right
tool can help.
One of the most commonly recurring tasks in
switch cabinet construction is the crimping
of cables. This task is usually carried out
using mechanical 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 re-
curring basis. With a manual force of up to
20 kilograms per crimp, excessive strain in
the wrist and forearm can occur over time.
48
One key factor is considered to be the
number of 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 affected, the use of a tool
with motorised drive is recommended for
higher numbers of 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 come
from the hand and forearm is around 90 percent
less than that required for a tool operated
purely by hand. “When we developed our
electromechanical micro, the aim was a
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 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 tool should cover the
broadest range of tasks possible.
The electromechanical tool from the afo-
rementioned manufacturer, for example, is
able to process cable cross-sections from
0.14 to 50 square millimetres with a crim-
ping force of up to 15 KN, with a long-term
time saving compared to the mechanical
crimping tool.
Because, in terms of the system concept,
the tool is designed to take the interchange-
able dies from Klauke’s 50 series, it is also
suitable for crimping various cable types, The sequence is always the same: first, the
cable end-sleeves, and also tubular cable manual pre-clamping. When the operating
lugs, insulated solderless terminals and pin lever is actuated, the crimping jaws close in
cable lugs. order to fix the connectors. During this par-
ticular step, the material can be precisely
This not only makes the tool a versatile aligned and positioned. In the second step,
companion for switch cabinet construction, the crimp is achieved by the force of the
it is also gentle on the joints and allows con- motor.
sistently fast operations for numerous other The operating lever simply needs to be
manual and industrial applications. depressed fully and the tool automatically
starts the crimping process, which takes no
more than 1.5 seconds, depending on the
material.

49
Employee health:
Less physical effort thanks
to electrically-driven tools
Once the crimp has been made, the ope-
rating lever is released to initiate the return
movement, also fully-automatic, into the
original position.
Electromechanical crimping tools reduce
the physical effort, and offer the following
advantages too: they not only achieve the
best crimping results for minimum force,
they also guarantee the consistently high
quality of these results for years afterwards.
This is because a suitable tool in faultless
condition is crucial to avoiding under-crimps
and over-crimps.
Otherwise, the consequences can be ha-
zardous: incorrectly-made crimps can, for
example, increase joint resistance which
can in turn cause temperature rises and
ultimately cable fires.
50
When choosing a tool, simple and reliable
operability is the key to ensuring safety.
Costs against benefits:
When is the 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 crim-
ping tool. Any concerns about the durability
and reliability of the electrical variant are un-
founded. For its micro model, for example,
Klauke states a long service life if the ser-
vice intervals are maintained (at 35,000
press cycles). The 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 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 tools give no cause for 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 ten square
millimetres in accordance with DIN 46234.
Despite this high efficiency, the total weight
of the tool, including the battery, is just 960
grammes.
Conclusion
The decision to invest in an electromechanical
crimping tool should be made according
to economic calculations. For specialist
operations in which large numbers of con-
nections have to be processed quickly,
purchasing such tools makes perfect sense.
Electro mechanical crimping not only in-
creases the efficiency of work processes, it
also protects the health of employees. And
since maintaining good health also means
sustaining physical strength, such an added
investment can benefit employer and em-
ployee in equal measures. Especially in light
of demographic change and the shortage
of specialists this brings about, physical fit-
ness has become an economically valuable
asset which must be sustained for as long
as possible.

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
an electromechanical tool.

51
Video advice for you!
From our headquarters in Remscheid, our Applications Engineering team offers an extra special
service.
You can not only discuss pull-out tests for your particular application with our experts, we can also
advise you by video. With this video advice, you as a user simply remain at your work place with
an Internet-capable PC. We can demonstrate to you via video transmission, and you can show us
things too, if you have a webcam.
The benefits at a glance
• Competent advice directly from the manufacturer
• Live presentation of the application with the chosen product
• Direct answers to your questions
• Availability on working days by agreement

© 2016 Gustav Klauke GmbH. All rights reserved. Subject to change without notice. BRFACH16GB 01/16 I
Service for your tool!
Our internal Service Center in Remscheid and the more than 60 Authorised Service Centers (ASC)
worldwide, with their comprehensive technical maintenance and repair service, ensure that Klauke
tools have maximum functional capability and guarantee secure connections.
The service centers offer a range of services, from regular tool inspections and checks of pressing
quality through repairs to a free tool hotline and equipment hire service.
By the way: Our mobile service van can be deployed for on-site operations upon request!

Gustav Klauke GmbH

Auf dem Knapp 46
D-42855 Remscheid
Phone: +49 (0) 2191 / 907 - 0
Fax: +49 (0) 2191 / 907 - 141
Email: info@klauke.textron.com This and further information
Website: www.klauke.com can be found here!