Crimp kit arrived. Crimps auto-terminals on wires from 0.5 mm² to 6 squares and all that are crimped according to the same principle; insulated terminals three colors-sizes and limit switches NShVI (NShVI2).
Who cares what happens if you mix point 18, several dozen correctly and incorrectly crimped terminals and a lot of time, read on.
Package
The pliers come in a regular gray bag without bubbles. They are not needed, the contents of the parcel can be destroyed only purposefully, it is simply difficult to damage it using the methods of our mail.There is no factory packaging, such as a blister or a box, the postal package has long been lost and there is no point in photographing it. Will go for a gift. And in general, I do not like unboxing reviews.
Appearance
Rectangular bag made of thick fabric, the shape is apparently given by two pieces of cardboard inside. Dimensions 28 * 14 * 4 cm. A little less than a sheet of A4 paper. Has a carry tail. Zipper on the outside on three sides of the bag.
Let's see what's inside.
Interior
Inside are the press tongs themselves, a screwdriver, interchangeable dies and spare screws.The first smaller (0.5-1.5mm²) die for crimping the auto-clamps is already installed in the pressing tongs.
The screwdriver is stored under the rubber bands on the side wall of the bag.
The screwdriver is double-sided, on one side there is a cross size PH1 for adjusting the ratchet actuation force. On the other side is a 3mm hexagon for changing dies. The screwdriver is not magnetic, the rod is fixed in the handle with a spring-loaded ball. 
Three more matrices are in the pockets of the bag. There are also 4 spare screws for changing dies.
Hex socket head screws, regular M4 thread, no problem to replace. 
The pockets close with Velcro. Life hack - you can put all the matrices and screws in one pocket - they fit perfectly - and take the other three with bags with terminals different type. Or matrix + terminals for this matrix in this pocket. I will probably do so.
The bag is universal, it has two more free places. One place is for the stripping pliers, the second is for the MC4 solar panel connector keys.
For example, such a lot
Ticks
The pliers are made of metal plates about 2 mm thick.
Plastic handles with rubber inserts. The handles do not stagger, it was not possible to remove them with the usual effort - the handles are latched into the latches. They won't slip, they won't need to be glued. metal base goes to the end of the plastic handle - the magnet sticks to the end of the handles.
The rubber inserts are marked ++++, I thought that the second handle would have a ---- sign, but both have ++ marked.
Pincers are assembled on rivets and pins. Inside you can see two springs, one small for the ratchet triggering mechanism, the second, large, the main one is covered with a lid.
The pliers have a gear wheel fixed with a screw. By turning this gear wheel, you can adjust the final position of compression of the dies. That is, you can make the ratchet open when the matrices do not fully converge.
The screw on the ratchet can be unscrewed with the cross end of the supplied screwdriver.
There is also a lever near the ratchet, by pulling which you can interrupt the crimping process and open the jaws of the dies.
matrices
The width of all matrices for these pliers at the point of attachment with screws is 4 mm.
First Matrix JX 1601-08
crimps auto-terminals from 0.5 mm² to 1.5 mm². The width of the first die at the crimp point is 7 mm.
There is a step inside the matrix, so this matrix compresses the terminals in one pass - both insulation and conductors at once.
We take the most common auto-terminal, insert it into the matrix and fix it with one click of the ratchet.
The stripped wire is inserted into the terminal and crimped with one push before the ratchet engages.
The wire must be stripped so that the cores are crimped in that part of the terminal where the cores are crimped, and the narrower and longer whiskers crimp the insulation.
Well, the process of crimping in GIF. Full video at the end.
Crimp result terminal 6.3mm wire 1.5mm², die space 1.5
I tried to crimp other terminals, the wire must be selected for a specific terminal.
On the right are well crimped terminals, on the left are terminals for which the wire is too thick.
Terminals and wire must be selected, you cannot just take a terminal designed for 1.5 mm² wire and crimp 0.75 mm² wire in it. It is necessary to either fold the wire twice or select a terminal with a smaller crimp mustache. Otherwise the wire is not held properly. Similarly, with a large wire size, when crimping a 2.5 mm² wire in a terminal for 1.5 mm², in whatever matrix it is crimped, the wire will be crimped poorly and the edges of the antennae will not wrap back into the cores and insulation, they simply will not be long enough. You can see for example such a lot -
it has six kinds of ring bare terminals for different wire diameters, including this matrix. In the picture, a wire with a cross section of 0.3-1 mm² can be crimped into the terminal on the left, and 8-10 mm² into the terminal on the right, and the terminals are, as it were, the same size.
Terminal and wire sizes
About the same with flat auto terminals. For example lot
Identical terminals under different sizes wires.
It is difficult to find a seller with a wire size chart. Even this seller does not have a description for all terminals which wire can be crimped. We have to determine the diameter of the wire empirically. By the way, I recommend the seller, it comes from him quickly.
And an interesting reference to how the crimped terminal should look right and what errors are possible during crimping. Everything is in English, but with pictures everything is clear even without knowing the language.
Second matrix JX2546 crimps wires from 2.5 mm² to 6 mm². 
The width of the die at the crimp is 6 mm, a thinner die can put more pressure on a thicker wire. 
there is no step in it and you need to crimp it in two passes - first the cores then the insulation. 
The terminal is also inserted into the matrix, fixed with a ratchet, a wire is inserted and the wires are crimped. 
Then the clamp is inserted into larger size and the insulation is crimped. In the photo, the ring terminal with a 2.5 mm² wire is crimped in the 4mm position - core and in the 6mm position - insulation. So the place of crimping in tongs must be selected for a specific wire section and terminal. 
Similarly, the 9.6mm terminal is crimped onto a 6 mm² wire - the cores are in the 6 mm position and the insulation in the same position is not clicked. The insulation would need to be crimped in position 8 or 10 if there was one, but since the matrix presses a maximum of 6, it is necessary to crimp the insulation in position 6. 
Well, GIF crimping. 
Third matrix crimps insulated terminals in three colors. 
The color of the position in the matrix indicates the maximum wire diameter that can be crimped. Blue is the largest, red is smaller and yellow is the smallest. We take the red insulated ring terminal NKI 1.25-3 and crimp it onto a 2.5 mm² wire. 
If the wire does not completely fill the hole in the terminal, it will need to be crimped in a different color position. 
Well, the crimping process in GIF as usual 
Fourth matrix JX1601-06 crimps NSHVI tips from 0.25 to 6 squares. 
Compresses like a trapezoid. 
Tips NShVI are designed to make a stranded wire rigid, for example, to insert a stranded wire into a terminal block.
AT different countries different standards for the color designation of the wire section for the NShVI tip. For example, here is a table of colors and wire sections that are customary to use with us.
According to this table, lugs with a section of 6 mm² have a length of 12 or 18 mm, a matrix width of 12 mm - that is, the width is enough to crimp the lugs most commonly used in length. Elongated ones are rare. 
It is easy to crimp - we select the tip so that it fits snugly on the wire cores and press in the place with the corresponding designation in the matrix, we didn’t have to select anything here. Crimped several tips, the result is visible in the photo. 
Animated picture of crimping NShVI 
Video version of the review of ticks:
Pros:
- Enough universal set, which can crimp the most common terminals for stranded wire.
- Carrying storage bag, there are two empty places under the elastic bands and a place without elastic bands - you can store a supply of terminals inside the bag.
- The price of the set, it is possible to buy the same set with an insulation stripper a little more expensive than this.
- Spare screws are not in vain included in the kit, while writing a review, I changed the matrix 10-15 times, tore off one screw, the thread in the tongs is intact.
The product was provided for writing a review by the store. The review is published in accordance with clause 18 of the Site Rules.
I plan to buy +60 Add to favorites Liked the review +60 +97When working with wires for various purposes, it constantly becomes necessary to connect them to electronics or other household appliances. To accomplish this task, it is customary to use special tool- pliers for crimping the lugs of a particular cable. This article will provide general information about this type of press, what types they are conditionally divided into and how to use them during installation or repair work.
Due to the fact that with the development of technology, new types of cable connections were invented for for various purposes, With different power and conductivity, their design also changed. In order to prepare the contacts of the leading wires, their lugs should be crimped in an appropriate way. The solution to this problem was the use of crimping pliers.
Very often they are used by radio amateurs, auto mechanics and electricians. Such a tool can be used to press the contacts of both conventional cables and specific connectors for non-standard connectors (network cable for a computer), various terminals. To date, crimping pliers are considered one of the most common tools for such work. It is cheap to produce, affordable and effective.
Its design allows you to effortlessly press the tips. The principle of the press is capable of reliably and efficiently crimping cables. As a result, there is a very strong connection between all conductors and the connecting structure itself. The cost of a crimping tool can usually be affected by several factors - the manufacturer, the type of construction, the quality and material of the final product.
Tool types
First of all, it should be noted that there are now many manufacturers of crimping pliers that make them to various standards. In the end, you should get a tool that can have a narrow purpose (pressing only a certain kind wires), and wider ( universal pliers for household structures and production). For this reason, the consumer should immediately have an idea of what type of pressing tool he will need.
AT living conditions such a crimping tool may be suitable for working with stranded wires electrical network: sockets, switches, lighting, energy meters and more.
Pressing tongs provide a high-quality and safe electrical and mechanical connection. Usually, the division into types of a given instrument is made on the basis of them. Crimping pliers are classified as crimping equipment. They are often required to work with low current systems to secure contacts.
So the tool itself can be divided into several types depending on its purpose. For removing the sheath from the cable and its insulation. This type of pliers allows you to quickly and accurately cut off the required section of insulation on the wire without damaging the core itself. They can be adjusted to a specific diameter that should be removed from the core. The setting can be done manually or you can choose automatic.
With manual adjustment, there will still be a chance of damaging the wire itself, and automatic adjustment will allow you to remove the braid under the consequences for the cross section of the cord. Often this type is used when working with distribution and junction boxes. The cutting edge must always be sharp so that the cutting of the outer insulation is done in one step, without chewing the wire in the tool.
For end sleeve presses. For this type of ticks, there are also several types, depending on the shape of their nests and shape. Nests can have plastic flanges, as well as be made without them. Able to be trapezoidal or intended for square pressing. Those that have sockets with plastic flanges in their design allow you to effectively crimp the lugs of stranded wire, and their square shape is able to ensure reliable contact of all strands. With such tongs it is very convenient to do mounting or centering for any type of section. For a more reliable and accurate contact press, the pliers must be selected according to the appropriate diameter (there is a color marking for them).
For insulated tips cable. Working with insulated contacts should be carried out with an oval-shaped tool. Usually in their matrix should be located 3 standard forms for the press, which can be distinguished by the colors - red, blue and yellow. Accordingly, for each of these colors, a tip, sleeves and other connectors are produced with the same color indicator.
Applying while working with insulated wires such pliers, it is imperative to ensure that the position of the butt edge is correct. The butt edge is located in the middle of the upper profile of the tongs. This design is dictated by the fact that with its lateral placement, the edge will be able to violate the reliability and tightness of fixing the cable itself.
For the press bare lugs cable. Used for non-insulated type of wire, as well as for open, made of brass. For the press in such pliers, a special rod is made. Therefore, the sleeve itself is crimped in the center, and the rod must be planted on the separation seam. Press pliers for open ends, which are made of brass, can be used for certain types of clamps. One is for the wire and the other is for the insulation. In order for the press of open contacts to be reliable, it is worth attaching a locator to them. Such a device will ensure accurate positioning. If it is necessary to crimp the terminals, it is better to use suitable crimping pliers.
Video “Clamping and Insulation: Electrical Basics”
Principle of use
The principle of using contact press pliers in wiring can be understood from the workflow in which they will be required to be used. To work, you need a certain wire, the crimping tool itself and the connecting element itself, which should be placed at the end of the contacts. First of all, the outer insulation must be removed from the end of the wire. To do this, you need to use pliers. They should have a semicircular hollow, and on top of it a cutting edge. You need to put the wire in this recess, then press the upper side with the blade. After making a couple of turns around the cable, the insulation will be cut. Now it can be removed without effort. For the correct press with reliable contact, it will be enough to strip 4 centimeters of the cord.
The next step is to align and place all the strands in desired sequence, as required by a certain type of connector. When the wires are straightened, they should be pressed tightly together and cut off, leaving 1-1.5 cm of contacts for connection. Then all the contacts must be placed in the connecting device itself, while maintaining their sequence. The vein establishment must be made to such a depth that the lower notch of the connector reaches the cable insulation. This is necessary in order not to damage it during crimping, since the notch itself is pressed very tightly, fixing the device on the cord.
After that in seat ticks should be placed device. Be sure to check the consistency of the colors of all cores. When they are in correct position, then compression can be performed. Final stage requires checking the connection for strength, as well as whether the connector itself is intact. Since there are a large number of working tools for such purposes, you can choose exactly those that are best suited for a particular type of connection.
Various household and not only appliances require connection to the electrical wiring available in the building. And often for this you have to carry out special preparation of wires. To make this task easier, experts often use such handy tool like crimping pliers. Not all home craftsmen are aware of this, so it will be useful for them to find out what this type of press is, what types it is, and how to handle it during repair and installation work.
general information
As man created new types of technology, new types of cable connections for various purposes, power and conductivity appeared. In order to connect the equipment in accordance with the current requirements and regulations, it is necessary to prepare the contacts of the leading cores in a special way. To do this, you need to properly crimp their tips.. This is exactly what special crimping pliers were created for.
This is one of the indispensable tools that many radio amateurs, auto mechanics and electricians must have in their arsenal. With the help of such pliers, it is possible to crimp the contacts not only of ordinary cables, but also of specific connectors for non-standard connectors. Despite the fact that in recent years the range of tools for conducting electrical work has significantly expanded, pliers for crimping tips are still one of the most popular tools for performing such an operation. This is largely facilitated by the low cost of their production, availability and high efficiency.
Such ticks have quite simple design, thanks to which it is possible, even without special electrical knowledge, to crimp the tips. Such a press is a very reliable device with which you can crimp cables quite well. This guarantees a strong connection between all the conductor mi and directly connecting structure.
To date, there are enough a large number of crimping tool models, which may differ not only functionality but also cost. The latter may depend on several factors:
- press manufacturer;
- construction type;
- quality and material of the final product.
Tip Description
Most cable lugs are marked with four letters - NShVI. In the deciphered version, this abbreviation will sound like "insulated pin sleeve tip." To put it in a more understandable language, this is a common sleeve for a flexible stranded wire. Its main purpose- protection of the end of the cable, which is used for fastening in a screw clamp terminal. After removing the insulation, a lug is put on the end of the cable, and then it is crimped with a special device. Most often, press pliers are used for this.
The metal part of the tip is most often made of electrolytic copper. It has insulation only on the back side. The thickness of the insulator is noticeable larger diameter metal part of the tip. It looks like a cuff. The tip is attached to insulating coating wires. Crimped it metal part , which fixes inside the cable core. When creating a connection between the handpiece and the screw clamp, the entire metal part is hidden in the socket of the device. Only the safe dielectric part of the cable is visible from the outside.
Tool types
If you go to any store that sells electrical products, you can be amazed great variety the crimping pliers offered there. Such a wide range due, among other things, to the fact that each manufacturer uses its own standard in the manufacture. This explains why such tools can have different functionality.
For example, in stores you can find highly specialized pliers designed for crimping wires of only a certain type, and a wider-purpose tool with which you can crimp cables when connecting and repairing not only household appliances, but also production equipment. Every consumer should know about this and take this moment into account when he goes to buy a press for crimping tips.
With the help of crimping pliers, you can create a high-quality and safe connection of an electrical and mechanical nature. It is this feature that is one of the main features of the classification of the instrument in question. It should be said what is the crimping pliers represent a class of pressing equipment. In most cases, they are used when working with low current systems to ensure reliable fixation of contacts.
Crimping pliers can be classified into several types depending on the purpose.
For stripping the sheath and insulation of the cable
By using this type pliers can quickly and fairly accurately cut off a certain section of the insulation on the wire, while maintaining the integrity of the core itself. Modern crimping pliers often have the ability to adjust to a certain diameter so that you can easily remove the insulation from the core without risk of damaging it. This setting can be done in two ways:
- manually;
- automatically.
When trying to manually select suitable diameter there is a risk of error and damage to the wire. Therefore, it is best to make such a setting automatically. Then you can be sure that the removal of the braid will be done without negative consequences to cut the cord. It is this type of preparation for crimping that is used when working with distribution and junction boxes. Special attention needs to be addressed to cutting edge which should be sharp. Then the outer insulation will be removed in one step without the risk of "chewing" the wire into the tool.
For end sleeve press
For this type of operation, several types of hydraulic presses are offered for sale, which may differ in the shape of their sockets and the shape of the tool. There are models in which the sockets are made with plastic flanges, but some can be made without them. They can have a trapezoidal shape or be designed for crimping square-shaped cores.
Pliers whose sockets are equipped with plastic flanges should be selected when stranded wire lugs are to be crimped. With this task, they will perfectly cope thanks to square shape, which can ensure reliable fixation of all cores. Pliers of this type are ideal for mounting, as well as centering cables of any type of section. If you need to perform a more accurate and reliable crimping of contacts, it is necessary to choose pliers with an emphasis on the diameter of the cable.
For insulated cable lugs
If the wiring has insulated contacts, then a hydraulic press for crimping oval-shaped cable lugs should be selected. According to the standard, their matrix has three forms for the press, each of which corresponds to specific color: red, blue and yellow. And for each of these colors, there is a tip, sleeves and other connectors for sale that are designed to be used with it.
About to crimp insulated wiring using a terminal press of this type, care must be taken to ensure that the butt edge is correctly positioned. It should be strictly in the middle of the upper profile of the pincers. Compliance with this condition is great importance, since when placing the edge on the side, the reliability and tightness of fixing the electric core will suffer.
Such pliers are designed to work with a cable without insulation, as well as open-type conductors made of brass. In the design of such a tool, a special rod is provided. Crimping is carried out strictly in the center, while the rod must be planted directly on the separation seam. A slightly different design has pliers for crimping open lugs made of brass.
They have two types of clamps, among which one is for wire, and the second is for insulation. To perform the most reliable crimping of open contacts, it is recommended to attach a locator to them . This is very convenient fixture , with which you can ensure the exact position of the contacts. If the task is to crimp the terminals, then it is best to do this with special tongs for pressing plugs.
Principle of use
Understanding the principle of operation of pliers for crimping insulated lugs in wiring is not so difficult. To do this, it is enough to know the nuances of the workflow itself, during which it may be necessary to use them. In addition to the wire whose contacts need to be crimped, you will need a crimping tool and a connecting element that is attached to the end of the contacts.
During the installation and repair of various home appliances often have to work with wires. And for their quality performance, often reliable and secure connections are required. solve this problem without specialized tool impossible. Most often, crimping pliers are used for this. Today, such a tool is on sale in a wide range, which makes it possible to choose the most suitable option taking into account the task facing the specialist.
However, the choice of pliers for crimping cable lugs is not simple task as it might seem at first. Even though you can find universal pliers in stores to perform such work, it is still recommended to choose a highly specialized tool that can guarantee the highest quality crimping of contacts. Accordingly, the crimping of the tips itself must be performed by a specialist, since for the quality of such work, it is necessary to have experience and knowledge.
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 at, UZO, sockets, switches, chandeliers, lamps, counters electrical energy etc.
For production purposes, we have a hydraulic press that can be used to crimp conductors 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 terms"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. Recently, I have been using to remove insulation.
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.
Content:
For high-quality connection of contacts of devices, equipment, crimping of the ends of the cable and wires that are connected to them is used in electrical engineering - this method gives an excellent connection of conductive surfaces. In order to use crimping, you need lugs or sleeves that have different kind and appointment. The crimping method requires a special tool. Consider what tips are and how they are crimped.
Types of tips for crimping
For every inhabitant, a striking example of incorrect wiring is the stair switchboard, many apartment owners have melted wires in the switchboard, there are twists. Ferrules for wires for crimping can save citizens from the possibility of heating and ignition electrical wiring as a result of poor-quality wire contact, the absence of cable lugs.
When there is good contact between the cable or wire being connected and the connection device, the transition resistance is minimized, and with an increase in current load on the contact group, they can heat up in case of poor contact. Sleeves and tips are intended to remove or minimize the contact resistance, in other words, to exclude poor-quality contact, for a bolt or screw.
For crimping (crimping for lugs) of wires and cables, special products are used - lugs and sleeves. Tips can be stranded wires and single-core wire, they are subdivided according to the purpose and type of wire for which they are used (copper or aluminum).
For crimping the copper conductors of the cable, lugs made of seamless copper tube, which is flattened on one side and has a hole for a screw connection. This type of tips happens:
- With different diameters for a wire and a mounting hole that does not have protective coating;
- for crimping electrolytic tinned with different holes for fastening.
The marking of this type of tips is as follows:
- uncoated, TM - X - Y, where X is the cross section of the wire, Y is the size of the hole for fastening;
- coated, TML-X-U.
There is another type of lugs with a control window, these are tinned copper products for terminating cable and wire cores. A feature of this type is the ability of the termination performer to control the correctness of crimping through the control window. This type of product is marked as TML (o), it is noteworthy that they can be installed on the ends of cables using solder and soldering, which almost completely removes the value of the transition resistance.
Quite often in electrical engineering there is a connection aluminum wire with a copper cable, in this case it is recommended to use aluminum-copper lugs for high-quality connection of the aluminum wire and the shield copper bus.
Decreasing overall dimensions devices and devices, pin products have become popular tips for ending. They are used in electrical equipment and circuit breakers in protection devices. With the reduction of clamping fasteners, the pin is the most optimal solution for good contact. This species is marked as NSHP.
Tips NShVI
Cable lugs for crimping NShVI are a pin sleeve product with insulation. Electrolytic copper is the material from which it is made, insulation is installed on the back side, which is thicker than the metal part. When the terminated wire is inserted into the socket with this lug, only its insulated part remains under the clamp. In industry and in everyday life, this type of lugs is used for cables up to 35 sq. mm in cross section, they are pressed with a special tool.
There are several modifications of this tip, which differ in the number of wires connected in one tip. For two cables, the marking has the form NShVI2, there are no structural differences in this tip, the same metal part and PVC cuff, but the diameter of the sleeve (skirt) is larger, designed for two wires.
Features of working with NSHVI
Cable lugs of this type are intended only for multi-core cables, they cannot be used in the termination of wires with one core. For rigid (single-core) wires, crimping is used with bushings (sleeves) without insulation. Crimping of stranded wire is carried out as follows:
- the cross section of the wire is selected, the brand of the tip is selected, into which the cores must enter freely and tightly from the side of the skirt;
- in practice, the type of tip is selected with some margin. Example: PV-3 wire with a cross section of 1.25 sq. mm can be terminated with a tip from 1.5 sq. mm. Skirt section - up to 2.5 sq. mm.
Tool
Crimping of cable lugs is carried out with a special tool that is designed and manufactured for this purpose. A tool is necessary for crimping the lugs, since a person with a simple effort cannot create the necessary force for high-quality termination of the cable core. Which crimping tool to choose depends on the cross-section of the wire or cable that is being worked on. We list the most used tool:
- Press tongs of the PK2 or PK2M brand are a hand tool that is used in terminating the cores of wires and cables with a cross section of up to 10 sq. mm.
- Press tongs of the PK1 or PK1M brand are a reinforced version of manual tongs with long handles, they can make the end of lived up to 50 sq. mm.
- Tongs are hydraulic, manual, which without much effort can terminate the core up to 10 sq. mm.
- Hand press, which is used in industrial production for a wire with a section up to 240 sq. mm.
- Hydraulic press with electric drive or foot pedal, cable ends up to 300 sq.mm.
Crimping sleeves
Not in every device or device, switching an external circuit uses cable lug, there is also a sleeve ending, its choice is made according to the type of connected wire (copper, aluminum). For cables with copper conductors - marking of GML sleeves, where:
- G - product name, sleeve;
- M - the material from which it is made, copper;
- L - the product has a coating, tinned.
For aluminum wires GAO brand is selected: aluminum sleeve closed type. When it is necessary to make a connection with the transition of aluminum to copper, a product made of an alloy is selected. It is not allowed to use products for copper wires on aluminum conductors, this is a heat couple that will heat up due to an electrochemical reaction that takes place in the material of these conductors when connected.
Preparing for pressing
You can’t just put a cable tip on a core, you need to perform a number of preparatory steps:
- clean the desired length of the end of the wire or cable from insulation - you can use a special tool, a stripper;
- we twist the cores by hand and insert them from the side of the skirt into the tip;
- first, the tip is selected according to the cross section of the core, observing the conditions for free and tight entry into the tip sleeve.
Crimping of wires with tips is carried out with a special tool. On each press there is a marking of matrices and the main part according to the type of tip or the cross section of the core. Now the color standard is observed, for this reason it is easy to combine the section and the matrix in the desired position.
How to crimp a wire
In the event that you have not previously crimped cable cores, you need to practice on unnecessary pieces of wire or cable. To obtain a high-quality connection, you must adhere to the developed rules:
- The cable inserted into the sleeve (sleeve with a flare) of the tip must be held by hand in the socket.
- After making sure that the matrix matches the selected tip, you can begin to squeeze the handles of the press until the ratchet mechanism is activated and an audible click.
- The ratchet mechanism of the press simplifies the pressing process. The mechanism does not allow the press to unclench, and when the wire is crimped unsuccessfully, it must be unlocked.
- Double-circuit crimping compresses the insulated part of the ferrule and the metal contact. Such a matrix has two sockets, they are different in size, so you need to carefully look so that the cuff fits into its socket, and the metal contact of the tip into its own.
Conclusion
Each tip must correspond to the wire, most common mistake in crimping cable cores, it consists in a mismatch between the selected tip and the material of the wire; you should not put on a too loose sleeve on the wire. Do not use products large diameter for termination of conductors of a smaller cross section, this can lead to an increase in contact resistance and heating of the contact. You can not cut the sleeve into two parts in order to save products, do not use homemade tips.
For high-quality crimping of cable cores, it is necessary to use a special tool, a chisel and a hammer will not be able to make the necessary compression, to give high-quality contact.
