Press tongs for crimping nshvi bushings. What are nshwi tips and should you use them? Crimping tools and their disadvantages

- Of course, all tools (with the exception of some consumables) are guaranteed for a period of 1 to 5 years, specifically for hydraulic presses - 3 years.
- At standard work It is recommended to change the oil at least once every two years. If the tool is used frequently, the oil should be changed more frequently. It is not difficult to determine the frequency of oil changes - if the press starts pumping too slowly, or jerkily, then it's time to check and top up or change the oil. When buying a hydraulic tool, you can immediately purchase KBT Hydraulic Oil for subsequent maintenance.
- The resource of the tool is a loose concept. It depends on the intensity of use of the press - you crimp two tips a day, two hundred or two thousand. From the dimensions of the tips - if you crimp only the tips with a section of 25 mm², then the tool will last much longer than if you crimp the tips with a section of 150 mm². And so on.
  According to world standards, the service life of hydraulic tools is about 5,000 crimps, for pressing tongs - up to 10,000. The actual resource of the KBT tool reaches 10,000 and 30,000 pressings, respectively. But that's not the point. The main thing is that with the correct use of the tool and its timely maintenance (replacement of sealing rings, topping up and oil change), the KBT tool is guaranteed from three to five years (depending on the type of product), which best characterizes its resource.
- Yes, they fit. In the models PGR-300 "KVT", PGRs-300 "KVT", PGRs-300A "KVT", PGRs-300AM "KVT", PGP-300 "KVT" and PGP-300A "KVT" matrices are the same. Also, sets of high-precision matrices of the NM-300 "KBT" series are suitable for all these tools.
- Matrices in these tools are made according to a certain “average standard”, which allows for crimping of aluminum and copper tips and sleeves made both according to Russian GOSTs and DIN standards. The quality of crimping with such dies meets all the requirements, and has been verified by many years of tool sales. But if you need to crimp the tip and be sure to get professional result, then we recommend using specialized high-precision dies of the NM-300 "KVT" series, designed for crimping certain series of tips.
- It all depends on the type of quick couplings used. If they match each other, then it is possible. Couplings used on the tool trademark"KBT" have the following characteristics: M22 thread with a pitch of 1.25. If your pump or press has the same thread, then they can be used with KBT equipment.
- Can. But for this, it is necessary to remove the fixed handle from the hydraulic presses, drain the oil, remove the rubber container, and only after that adjust the valve. It is not necessary to drain the oil from the pumps, but you will have to partially disassemble the case. Plus, the valve must be set correctly, which is quite difficult without practice. Based on this, it is better to leave the valve setting to the service center specialists.
- Each tool has its own advantages and depends on the frequency and conditions of its use.
  For example, a mechanical tool can be used at any temperature (including negative temperatures), hydraulic tools can only be used at temperatures from -15 to +50 ° C (the KBT tool uses frost-resistant oil). The mechanical tool requires minimal maintenance, and the risk of breakage is extremely low. With some mechanical tools, you can crimp the tip faster - just press the handles together once.
  It is more profitable to use a hydraulic tool if it is used frequently - working with hydraulics is much easier physically. Most KBT hydraulic presses are equipped with a two-speed pump stroke mechanism, which significantly saves time during crimping. The automatic pressure release valve in the PGRs models protects the tool from damage.
  In a word, the choice between hydraulics and mechanics can only be made by a person, knowing the conditions tool operation.
- Any work should be carried out on a disconnected line. If absolutely necessary, you can use a special tool that is designed for work under voltage and marked accordingly. As of today, there is no such tool in the KBT product line.
- The decision to buy a mechanical or hydraulic tool can be made by a person who knows in what conditions this tool will be used. AT this case, all-weather and all-weather power tool, requires minimal maintenance, is virtually indestructible and works faster (when equipped physical strength) than hydraulics.
- These are specially designed high-precision dies for crimping very specific series or standards of ferrules. 99% of the dies in an inexpensive tool are made according to some “average standard”, and they can be crimped different tips, but the quality of crimping still will not reach the professional level. Until now, specialized matrices at a price of about 80 euros per pair (one standard size) were available only from large European manufacturers. Now they are also in our assortment. Matrices fit the most popular models hydraulic tools - presses PGR-300, PGRs-300, PGRs-300A, PGRs-300AM, PGP-300 and PGP-300A. If you clearly know which tips or sleeves you will use, and the guaranteed quality of the work performed is important to you, then the HM-300 "KBT" series matrices are your choice!
- Such dies are used for crimping various tension, connecting and contact fittings and are made to order. There are four types of dies for each tool: round die "A" for crimping aluminum clamps (an example of designation A-24/PG-60 tons, A-54/PG-100 tons); round die "C" for crimping steel clamps (designation example S-17/PG-60 tons, S-44/PG-100 tons) hexagonal die "MSh-A" for crimping aluminum clamps (designation example MSH-13.8- A / PG-60 tons, MSH-60-A / PG-100 tons); hexagonal die "MSh-S" for crimping steel clamps (example of designation MSh-32-S/PG-60 tons, MSH-48-S/PG-100 tons); To order matrices, you must specify them inner size(depending on the fittings being pressed) and to which press it is needed. Matrix production time is about two weeks.
- The main difference between the KBT tool is that the assembly and quality control is completely carried out at the KBT Kaluga plant. Particularly critical parts are also produced at the factory, other components are obtained from third-party enterprises. The similarity with the tool of other manufacturers or sellers ends appearance, and then, if you do not look closely. Most of the parts that make up the tool differ from similar parts in tools from other manufacturers, which has been repeatedly verified when we were contacted with requests for the repair of third-party tools. We make every effort to ensure that the tool comes out reliable and of high quality. Work is constantly underway to modernize and improve existing models. Warranty repairs and post-warranty service are carried out on the KBT tool.

NShVI is Pin Sleeve Insulated Tips - if with a plastic skirt and NShV - if without it. They are needed in the electrical business a little more than nothing, because the topic, for the most part, is Kipovskaya. But people love it.

Therefore, let's look at some methods of crimping the tips, especially since there are many special crimpers for this task - a tool that can do nothing but compress bushings made of soft, thin metal.

To be pressed ... Then we will try to pull them off the end with our hands.

The wire is cut and stripped with a small margin solely for clarity.

Since this is not a comparative test, the crimper 2ART9303 from DKS immediately wins at the start, without undue intrigue.

Because he's sexy! And in an unexpectedly convenient pistol form factor. You just take it out, work calmly and comfortably, and everyone else suffers.

Presses this crimper with a square.

Presses on conscience. It does not wedge, the sponge does not warp. To crimp the six, a noticeable effort is required, and as a result, one of the tips could not be pulled off the wire by hand.

But similar in capabilities, capable of accepting from 0.25 to 6 squares, Chinese crimp HSC8-6-6

Presses hex. Tips pop off with no problems. A small one can also be pulled off, but it didn’t work on the camera after several attempts)

Another crimp with a larger caliber. Already up to ten square

Presses a square. Two and a half is too little for her, and the six is crimped so tightly that even the skirt flew off in an attempt to pull the sleeve off the wire.

And, finally, a universal tool for many tasks that already exists and cannot be better than... Side cutters!

It is enough just to bite the tip with them, fixing it on the wire, and the terminal, for example, of an automatic machine or any other that requires an effort of at least 2 Newton meters, will compress everything as it should.

It was not possible to pull off the tip from the six. He lost the skirt, as in the case above, but the little one fell off, which, again, indicates that it is better to use a crimper for small sections, including so as not to spoil the same small terminals with a small, as a rule, tightening torque , do not tear off the slots, do not lose the tips, but thicker wires and side cutters will fit.

Thank you for your attention.

Hold your tail with a gun, a gun from the DKS and masterfully use side cutters!

Hello, dear readers of the Electrician's Notes website.

In today's article, I will share with you information about the tool for crimping insulated lugs - these are EGI-60 manual crimping pliers made in Italy. They are also called "crimpers". At the end of the article I will show specific example how to work with them.

A bit of history. The Italian company EGI began its activity back in 1973 and to this day is engaged in the production and production of professional tool for electrical installation. To be honest, I have no doubts about the quality of this tool. Maybe someone will refute my thoughts.

Here is the packaging.

Appearance.

EGI-60 are designed for crimping insulated:

ring tips NKI
fork lugs NVI
pin round tips NShKI
flat and plug connectors RPI-P, RPI-M, RSHI-P, RSHI-M (mother and father)
piercing couplers OV
connecting sleeves GSI

The matrix (sponges) of the EGI-60 pliers allows you to crimp the cores with a cross section from 0.25 to 6 (sq. mm). These pliers are just right for domestic use e.g. for crimping flexible stranded conductors wires and cables for, RCDs, sockets, switches, chandeliers, lamps, electricity meters, etc.

For production purposes, we have Hydraulic Press, which can be used to crimp the cores of wires and cables with a cross section of 16 to 240 (sq. mm). I will talk about it in more detail in my next articles. Subscribe to the newsletter.

The device and parameters of the press tongs EGI-60

Pincers have the strengthened three-hinged lever mechanism.

The handles are made of high-quality plastic, and the body material is made of steel.

The length of the handles is 15 (cm), which allows crimping with two hands. Although it is not difficult to cope with one hand.

The handles are connected to the jaws using pins with retaining rings.

The EGI-60 has a ratchet mechanism that mechanically blocks the opening of the handles until the crimping cycle is completed.

Thus, the risk of “underpressure” due to human error is reduced.

If, suddenly, you have chosen a tip or a core of an inappropriate section and have already begun crimping, then the ratchet mechanism can be unlocked at any time using the “dog”.

This model does not have a matrix pressure regulator.

The weight of these ticks is about 500-600 (g).

The pliers are equipped with a non-removable cast three-position matrix (or in simple words"sponges").

There are three standard crimps in the die. Each crimp for clarity is painted in the appropriate color:

red - 0.25 - 1.5 (sq. mm)
blue - 1.5 - 2.5 (sq.mm)
yellow - 4 - 6 (sq.mm)

Manufacturers of insulated lugs, sleeves, connectors and taps specially produce them in accordance with these colors (insulating collars are painted), because it is very convenient for installation and speeds up the crimping process.

During crimping, each crimp puts a stamp on the body of the tip or sleeve with the following letter:

red - I (1)
blue - G (2)
yellow - E (6)

These letters are so small that I could hardly see them. And even the camera could not clearly focus on them. So do not judge strictly by the photo.

How to use press tongs when crimping insulated ferrules

Crimping is one of the reliable methods of contact connections. I spoke in detail about the advantages of this method in an article about - follow the link and read.

Now let's move on to an example.

Remember the most basic rules of crimping!!!

1. How to choose the brand of wire?

Crimping of insulated lugs and sleeves is possible ONLY on stranded (flexible) copper wires. For single-wire (rigid) wires, bare lugs must be used.

As an example, consider the crimping of copper wire PV-3 1x2.5 sq. mm (the new designation for this wire is PuGV).

2. What type and section of the tip should I choose?

The tips are not designed for one specific wire section, but for several ranges at once. Agree, very convenient.

Thus, for the considered wire PV-3 1x2.5 sq. mm, I chose the ring lug NKI 2-6, designed for a wire cross section from 1.5 to 2.5 (sq. mm).

The tip could be chosen not only as an annular NKI, but fork - NVI or pin - NShKI. It all depends on the operating conditions and connection method.

3. Stripping

We remove the insulation from the wire core to a length equal to the tubular part of the tip. To strip the insulation recent times I use .

It is the tubular part that is the point of contact of the wire with the tip - it can also be called the contact part.

The tubular (contact) part of the tip can be determined visually. Its diameter is somewhat smaller than the diameter of the insulating cuff.

After removing the insulation, the core of the wire must be twisted a little to avoid the occurrence of bends and plexuses of its individual conductors.

4. We put the tip on the wire

The stripped wire should protrude beyond the insulating collar by no more than 1 (mm), and it is better to be flush with its edge.

The insulation of the PV-3 wire must go inside the insulating collar until it stops with the tubular part.

We select the appropriate crimp on the matrix (in my example it is blue) and start the wire with the tip like this.

Because crimping is double-circuit (I talked about this at the beginning of the article), then make sure that one circuit compresses the tubular (contact) part of the tip, and the second - the insulated cuff over the wire insulation.

6. Tip crimping

We hold the wire from falling out of the tip and begin to squeeze the handles of the tongs until the ratchet mechanism is unlocked.

Crimping occurs by pressing to a certain depth the copper tip of the NCI into the copper flexible stranded wire PV-3 along the selected crimping profile.

After pressing in without fail checking mechanical strength the resulting connection and the integrity of the insulating cuff.

On the surface of the insulated cuff, an imprinted brand in the form of the letter "G" is visible.

Here's what happened.

And this is the view from the back.

P.S. Now you can imagine how to crimp insulated ferrules using EGI-60 pressing tongs and their analogues. Thank you for your attention.

The use of lugs when connecting wires is an opportunity to improve the quality of contact, thereby reducing contact resistance and heating of the site during the flow of currents. In addition, the safety of the cable is ensured when it is connected using a screw clamp.

The question is which product is better to use. Today, the following lugs for wires stand out - NShVI, TML, NKI, NVI and others. Consider their features, advantages and rules of application.

Decoding and purpose of NShVI

NShVI - type of tip, which is deciphered as follows:

"H" - tip.
"SH" - pin.
"B" - sleeve.
"I" - isolated.

This type of ferrule is used when crimping copper wires with a large number lived for subsequent connection to devices and assembly electrical circuits.

Pressing is carried out using special tool- tongs for crimping NShVI. In other words, the task of the product is to ensure high-quality contact and integrity of the cores when connected using a screw clamp.

Sleeve NShVI are used for copper wires with a cross section in the range of 0.5-35 square meters. mm. Once the product is installed, solid pins are formed at the ends of multi-core cables, making it easy to connect to a terminal or equipment.

Where are they used and what will happen if end sleeves are not used?

Connecting stranded copper wires without the use of NSHVI leads to damage to the cores, deterioration contact connection and subsequent burnout. In addition, damaged cores are subject to oxidative processes and rust faster.

Tips NShVI (KVT) have a wide scope. They are actively used when connecting sockets and switches, installing machines in electrical panel, connection of RCD and other equipment.

The popularity of a multi-core cable is easy to explain, because it has a number of advantages - flexibility and the ability to pass more current through itself (when compared with a single-core wire of the same cross section). But it is not suitable for screw connection. It is these clamps that are used today in the same AB, switches and sockets.

If you act without clamping, the strands are displaced by the pressure of the screw and damaged. As a result, the reliability of the connection deteriorates and the quality of the contact decreases.

Previously, soldering stranded wires was used to solve the problem, thanks to which big number Lives become one.

The disadvantage of the method is high costs time. If you need to install a dozen sockets and switches, on work will go not one day. The use of NSHVI allows you to avoid such problems and speed up the work.

During the installation process, it is worth remembering that the cross section of the wire and sleeve must clearly correspond to each other and be selected taking into account the manufacturer. This is the only way to avoid installation difficulties and damage to the cable. You can be sure that the connection will last for the entire time of operation.

Design and types

The product consists of 2 elements:

CONDUCTING TUBE. In the process of its manufacture, electrolytic copper with obligatory tinning is used.
POLYAMIDE FLANGE, INSULATED.

In simple words, NShVI cable lugs - copper tubes, processed by electroplating and having one flared end (for inserting a stranded conductor). The second part of the product is a polyamide cuff that provides reliable insulation and voltage protection.

A special type of copper is used in the manufacturing process, which ensures reliable connection at the point of contact and avoid damage to the conductor due to screw pressure. Today you can buy a NShVI tip with a cross section of 0.25-150 mm.

According to the design of the device, there are two types:

Single.
Double.

The first are designed to crimp one, and the second - two stranded wires at the same time. This is their main advantage. For example, when power is applied to the AB (circuit breaker), it is possible to exclude an additional wire jumper from the circuit. Based on the characteristics of each type, the size of the plastic flange varies.

In addition to the type of product already considered, there are other types:

Design nuances and characteristics

The NShVI tip, as a rule, has the following features:

In the manufacturing process, copper type M1 is used;
The upper voltage threshold is 690 V;
The connector surface is subjected to electrolytic tinning;
The dimensions of the connectors are designed for connecting one cable (installation is carried out taking into account the cross section);
Insulation is carried out using polypropylene, which does not contain halogens;
The insulating element is characterized by high thermal resistance - it can withstand temperatures up to 105 degrees Celsius;
Sleeve connectors KBT are made in one color and have common standard DIN. This is done in order to eliminate difficulties during the installation process. In addition, the color is selected taking into account the marking DIN 462228, part 4.
The conductor is crimped on top of the copper sleeve;
Cuff NShVI has a conical shape, which eliminates problems in the process of inserting a stranded wire into inner part bushings.

Product specifications are shown below.

Working methods

When using NShVI tips, the following should be considered:

COLOR "SKIRTS". The product shows the section of the connector. As a rule, we apply the KBT standard, which is characterized by the following:

Black - 1.5 sq. mm;
Blue - 2.5 sq. mm;
Gray - 4 sq. mm;
Yellow - 6 sq. mm;
Red - 10 sq. mm.

It is worth noting that goods from stores deviate from the standard. At the same time, the size of the product and the color do not correspond to the CBT. Minus - in low quality and rapid destruction. That is why, when choosing, you should pay attention to the color of the "skirt" and its compliance with the section.

PACKAGE. As a rule, NSHVI for pressure testing come in packs of one hundred products, which are packed in five pieces in a larger package. It is not possible to purchase such a product by the piece.

If you need to connect two cables, you should not "reinvent the wheel". NShVI-2 connectors of the same type of installation are on sale. For example, if you buy a product for four square meters. mm, it easily accepts two wires per 4 sq. mm.

Crimping tools and their disadvantages

There are two types of tools used for crimping:

Popular crimping tool

The following tool is used to install KBT tips:

WS-04A - the best pliers for beginners. With their help, it is possible to solve the main set of tasks in the process of installing various electrical circuits and assembling shields. Its functions include the ability to bite off and strip wires (cables) having a cross section of up to 10-16 square meters. mm. In addition, it provides recesses for NShVI tips up to 6 sq. mm. (if desired, a cable up to 10 "square" is included) or up to 10 square meters. mm. (includes up to 16" square). On sale you can find WS-04A tongs, which provide dies for crimping NShVI. Their disadvantage is that matrices can only handle products standard sizes up to 6 "square". If you use wires with an underestimated cross section (fake), the connection quality will be poor.
PKVk-10 is a universal tool that is used for crimping conductors of 0.5-10 sq. mm. But this is in theory, because in practice the situation is different. For example, a large force is required to crimp a cable from 6 “square” and higher, and if the crimping force is reduced, the quality of contact when crimping connectors with a small cross section deteriorates. Plus PKVk-10 - in compactness and the ability to crawl even into hard-to-reach place for installation (if necessary). The tool is best used for crimping conductors up to 4 "square".
STK-03 - powerful pliers that are suitable for large sections (from 10 to 25 "square").
PC-16. Such tongs are useful for crimping TML from 6 to 10 square meters. mm. The manufacturer sets an upper limit of 16 square meters. mm., but in practice, for crimping such a cable, it is required strong hand and great effort. In general, the tool is not very good, but has affordable price. On sale there is a version of PK-16u - a reinforced version, which is more durable. The tool is suitable for cases where crimping is rarely carried out.
PGRs-70 is a hydraulic press that is used for TML and sleeves. Many consider the tool as an alternative to the PC-16. The peculiarity of the press is the availability of interchangeable dies with different cross-sections in the range of 4-70 square meters. mm. With the help of such equipment it is convenient to crimp classic cables - by six, ten or sixteen square millimeters. It does not require a large load and excessive effort.
PKVsh-6 - used for crimping NShVI and NShV from 0.25 to 6 sq. mm., as well as a double tip NShVI-2 with a cross section from 0.5 to 4.0 sq. mm.

As for the Wiedmuller or Knipex pliers, their disadvantage is the large divergence of the handles. As a result, it is difficult to crimp the NShVI with one hand (the length of the fingers is not enough).

To avoid discomfort when performing work, it is worth choosing a tool from the position of ease of use, and not focusing on the brand.

How to crimp NShVI end sleeves?

Before crimping, the wire is stripped using a stripper, a special knife or a stripper. The first option is the most convenient and allows you to quickly get rid of the top insulation without damaging the cores. Stripping is carried out clearly along the length of the sleeve into which the conductor is installed.

As soon as the preparatory work is completed, a sleeve is put on the insulated part. Pre-select a pin sleeve lug (NShVI) of the required length.

When crimping, special tongs are used, which were mentioned above. In the process of doing the work, it is important to know how to use the press tongs. If you violate the technology, the quality of fixation leaves much to be desired.

To avoid errors, the sequence should be like this:

Introduction of the cleaned edge into the sleeve;
Installing the tip in the groove of the tool. It is important to ensure that the insulated part is pressed tightly against the body of the pliers;
Clamping the handle with sufficient force to ensure a secure fit of the connector.

If everything is done correctly, a reliable connection is obtained, and the structure itself is monolithic and strong. The principle of crimping using NShVI-2 is similar. The main thing is to accurately select the cable section. It's easy to do. The first digits show the section, and the subsequent ones (indicated with a hyphen) show the length of the working part.

WS-04A, which was mentioned earlier, is considered the optimal crimping tool in terms of price-quality ratio. Its peculiarity lies in the presence of lower teeth, which ensure reliable crimping of the product. Thanks to the groove, the connector is tightly compressed and cannot be removed.

During the installation of NShVI, consider one nuance - use the section one step below. What does it mean?

For example, if for a cross-module the allowable cross-section of a stranded wire is indicated, equal to 16 sq. mm., after crimping a 16-mm analog with the help of NShVI, the design will not fit into the connector. Here it is worth using a cable of 10 square meters. mm.

The PKVk-10 tool is considered no less convenient, but it is used for smaller sections. After crimping, the connector has a rectangular, and not trapezoidal (as in the previous case) shape.

The advantages of the tool are reliability and ease of use, but even with it there are “punctures” in the form of poor-quality crimping (this nuance should be controlled when doing work).

Clamping wires of different sections into a common lug

Most difficult task during installation (especially for beginners) - combining conductors of various sections in one connector. To avoid problems, you should adhere to the following rules:

Wire of larger and smaller cross section are diverted from each other. This can be done due to the different insulation of the conductors, as well as the diameter margin of the tip skirt. A thinner product is stripped a greater distance, after which it is shifted forward so that it is the first to end up in the tip.
At the second stage, the main wire is inserted into the ferrule until it stops and crimping is performed.

By a similar principle, it is worth acting in the case of double NShVI - first a thin conductor is started, and then the main wires are inserted. It is recommended to use STK-03 pliers for crimping. In the process of work, make sure that the tool does not snap into place. To do this, hold the ratchet lever while crimping.

What to do if there is no crimper on hand?

The situation is more complicated when there is no special tool for crimping NShVI. Here you have to search alternative ways crimping, so as not to disrupt the workflow. One option is tinning with a soldering iron, rosin and tin.

This option is good, but not suitable in all cases. In addition, the work takes time, and with large amounts of work, running with a soldering iron from one place to another is inconvenient.

Some "masters" use ordinary pliers for crimping. The essence of the technique is to press on the tip in several places for reliable fixation. The convenience of the method is undeniable, but when using it, there is a risk of damaging the cores. If earlier this method of installation was acceptable, today it is better to forget about it.

If there is not enough money for an expensive crimper, you can buy more available tool. There are many mites on sale that have decent performance in the price-quality ratio. In addition, it is better to take universal tools capable of performing several functions at once.

Double insulated tips (NShVI-2)

To crimp two stranded conductors, a special connector is used - NShVI-2. Its advantage lies in the ability to connect two wires at once, included in one socket of an electrical device.

In addition, if you need to install several conductors of the same section (for example, 4 by 1.5 sq. Mm.), It is also better to use NShVI-2.

It is useful in cases where it is necessary to separate the lines in the shield to different terminals or, for example, to bring neutral wire with RCD or AV to several terminals at once. Using a jumper in this case will not work.

Popular products in Russia

There are many factories producing NShVI tips in Russia. The leading position in this market segment is occupied by the KBT plant, which is engaged in the production of electrical installation tools and cable fittings, which differ high quality and affordable prices.

Today, the plant's product range includes more than four thousand items, which allows you to choose suitable tool and accessories.

The plant produces the following products:

Cable lugs and sleeves designed for crimping wires and cables.
Bolted lugs and connectors - for easy installation of cable cores. The peculiarity lies in the versatility and reliability of the contact, which allows the product to be used as component materials for heat-shrinkable cable sleeves.

For quality switching electrical wiring and cable routes with input distribution, grounding and other devices, it is important to use cable lugs. They crimp the ends of the wires. This is done not with bare hands, but with the help of a special tool.

Crimpers, or pliers for crimping wire lugs, guarantee high-quality contact and a reliable connection. They can be used for crimping tips various types- insulated and non-insulated, sleeve and sleeve. Also, the device allows you to compress automotive terminals.

Features of crimping pliers

Press tongs vary in size and shape of the matrix, but have a common purpose. A tool is used to fasten several conductors to each other or to prepare a bundle of current-carrying conductors for subsequent switching with terminals on electrical appliances.

Often the need for crimping arises when switching cables consisting of several cores. They cannot be placed in the terminals without proper preparation, because due to small vibrations during movement electric current some veins will be compacted. This will lead to the appearance of free space and, accordingly, a weakening of the contact.

This is what contributed to the fact that several decades ago, when there was no cable lugs, for the installation of power electrical wiring, only single-core wires were used. With the advent of press tongs, everything has changed significantly.

Despite the recommendation to use a single-core cable in power wiring, stranded wires were operated and crimped. Instead of pincers then (and now), the operation was carried out with the help of a powerful press that creates the required force. The principle of operation of the press resembles a car jack, and most models of equipment are equipped with a hydraulic drive. Today, bulky devices are used for high-quality crimping of a thick power cable.

The crimping process is trivially simple: a special sleeve is put on the end of the stripped cable, which is placed in the crimping pliers with subsequent fixation. Remember the network cable that is inserted into the rear socket system block: it is crimped with press tongs, and the transparent RJ45 tip acts as a sleeve. It's not the only one possible variant: there are double-sided bushings, on both sides of which the ends of different cables are inserted. As a result, we have a better and more reliable alternative to conventional twisting or soldering wires.

The main types and varieties of ticks

Structurally crimping pliers can be divided into two main varieties - diaphragm and those that work on the principle of pliers.

The second option is considered more common: when you press the handles, the tool squeezes the sleeve with two working planes, but, unlike pliers, there are cutouts of the desired shape on the edges that act as guides. This tool is suitable for crimping U-shaped ferrules.

The main advantage of the tool is its versatility, since it is possible to crimp the tips from any side. The versatility ends when it comes to sleeve sizes: specific pressing tongs are designed for a small range of sleeves.

If you often carry out crimping or this moment working on a major electrical wiring project, more it is likely that you will have to crimp the wires with cable lugs of both large and small sizes. Thus, on hand you need to keep several crimpers for different bushings.

There is a great alternative: crimpers with a set of removable dies mounted on a cassette. To change, the working part of the tool is inserted into the hole of the cassette, then it is pulled “toward itself”, and the matrix is inside. It remains to insert the base into the hole with the matrix of the desired shape. Remember high-quality razors with removable blades - a similar principle works.

With regard to diaphragm pressing tongs, they allow crimping from four or six sides. Exact amount depends on the diaphragm mechanism. The full circumference of the sleeve improves the quality of the connection, provides maximum crimp tightness. In addition, this device is automatic mode adapts to the thickness of the sleeve used, so there is no need to change dies.

But even such a tool has a drawback - you can crimp the end of one wire, since on the other side there is a closed "working head". Diaphragm pliers cannot crimp two wires instead of twisting them.

Application area

And now let's look at the main areas of use of press tongs for terminating wires. Depending on the specific situation choose a tool of the desired shape and design.

For stranded wires and thin-walled ferrules

These crimpers are used for crimping wires of small cross section (starting from 0.5 mm) with pin sleeve cable lugs. Quality equipment is produced by IEK. The crimping of the electrical cable is carried out to the maximum force so that the spring mechanism works.

The need for crimping a multi-core cable arises when it is connected to the terminals on circuit breakers, switchboards, boxes and other devices. The presence of high-quality bushings and tools eliminates fraying of the cable cores, since reliable crimping occurs, which ensures continuous electrical connection during switching.

Without cable lugs and subsequent crimping, it remains to either twist or solder the wires to the terminals of distribution and switchboard devices. In that case, be prepared to frequent breakdowns veins, disruption of communication with subsequent short circuits and equipment overheating. By the way, this option is still acceptable, but for a cable with one core.

For stranded wires and thick-walled ferrules

For high-quality crimping of power multicore cables with thick tips, press tongs of other sizes are used. Each individual tool is characterized by a unique working area. For example, for press tongs PK-16 from KVT there are five of them. Zones are marked with special marks on the jaws of the crimper. For example, the crimping range can be 1.5-16mm. After crimping, a special stamp remains on the back of the bushing.

Important! Many tools, including the PC-16, use stranded cable exclusively to crimp. If you try to do this with a single-core wire, then due to excessive force, the core may be refracted.

Pressing starts with preparatory phase. First you need to strip the ends of the cable, then insert it all the way into the sleeve, excluding the free space inside. That is why the sleeves must be selected according to the diameter of the cable so that it freely enters inside, but does not hang out there like a failed cork in a glass bottle. This is very important, since this criterion depends on the quality of the future crimping.

All protruding wires need to bite off. After that, insulation is performed: for this, heat shrink tubes with a hairdryer are used. To increase reliability, the upper part is wrapped with electrical tape. But this is completely optional: the tube will be enough.

Please note that tools can be marked with the letter "U" and without it. For example, in the case of the PK-16-U, the ratchet mechanism is located inside the handle. There will also be different efforts applied during crimping using PK-16 and PK-16-U. In the second case, less force is required.

For large cable

In the case of large power wire, a large hydraulic press should be used instead of pressing tongs. Such a crimp appeared much earlier than crimpers, but, as in the case with them, what kind of high-voltage cable can be crimped depends on its dimensions. In the domestic sphere, the tool is not used, since crimped bushings, lugs and sleeves have considerable dimensions. This option, for example, is suitable for laying and switching power wires in electrical panels at the entrances of houses, etc.

To compress the matrix, you need to apply a lot of effort to the lever. If the valve is slightly ajar, then the stem begins to slowly move away. The fully open valve ensures that the stem is quickly removed all the way to the stop. During full matrix compression, blocking occurs. At the same time, there is no possibility of overpressure that could damage the mechanism.

Since matrices are selected depending on overall dimensions, then the hydraulic press is released together with a cassette of several matrices. Top part magnetized, so it automatically returns to its original position. Only the lower element of the press changes. Regardless of the position of the equipment, parts do not fly out. The tool has a rubberized handle that increases electrical safety.

Crimping two wires with a double-sided sleeve is necessary in cases where the electrical panel is dismantled with subsequent transfer to another location. There is a need to build up copper wires with a cross section of 6-12 square meters. mm.

For serial crimping of wires

This option is excellent in that it excludes air from entering the sleeve. This is very important if you want to connect copper and aluminum wire which can be oxidized when exposed to oxygen.

For crimping computer cables

Crimping pliers for twisted pair cable used as a computer LAN cable are separate category. They work similarly to pliers with two jaws: instead of a metal sleeve, a matrix is used special form, which allows you to install an RJ 45 plug on a computer or telephone wire. Instead of crimping, such a tool displaces the contacts, cutting through the insulation on individual wires and pressing tightly to the cores.

How to work with crimping pliers

The process of crimping a cable with a sleeve or a ferrule is intuitively simple. The wire is placed inside one of the listed elements, to which a matrix of tongs is brought, the handles are squeezed and a high-quality contact is formed. In practice, everything is much more complicated than it seems. If this is your first time crimping wires, then surely the connections will be far from ideal. It is not uncommon for a seemingly well-made contact to deteriorate over time.

If the shape of the terminals is not maintained

The reason for this may be incorrect settings when squeezing the two jaws of the matrix. The forces applied and the shape are selected depending on the crimped wire and lugs. That is why, as mentioned above, two or more tools should be at hand so as not to have to constantly change the spring settings for different cables and sleeves.

The quality of the work performed depends on the material used for the production of the sleeve, and the thickness of the bushings and tips. Tight terminals are much easier to crimp: they are able to withstand the shape better than when using products made of soft material.

Also pay attention to important requirement, according to which you need to correctly place the tips of the U-shaped section. A certain skew of the part may go beyond the error zone.

Twisting stranded conductors before crimping

Experienced electricians who often solder and twist wires may be in the habit of doing this even before the crimping process. This action is strictly prohibited when crimping multi-wire lugs. It is very easy to check the validity of this condition: cross two stranded wires with each other, then squeeze them with pliers. You will notice how the wire is deformed, it will be interrupted, so the electrical connection on the current-carrying core will decrease.

Without twisting, the wire will be parallel, and in case of deformation, the wires will fill the voids, and there will be no squeezing.

Summing up, I want to remember a simple rule: for each job you need your own tool. This is a generalized concept, but in the case of press tongs, everything is much more complicated. If there is no desire to constantly reconfigure the spring, which is very difficult to do, then a separate device is selected depending on the type of wire being crimped. The final choice of which tool to buy and how many varieties to use, make depending on the quantity daily work associated with compression.