Dexter pliers for crimping wires 195 mm. Crimping tools for cable lugs. For insulated wire lugs

Every house, apartment or garage has an electrical connection, where it often becomes necessary to repair old wiring or install new ones. When laying electrical wiring is required, and doing it reliably, this is the key to correct operation electrical appliances and security. The best way to do this is with electrical cable crimps.

If the wires are loosely connected, for example, by twisting or soldering, the junction heats up, which most often leads to a fire. Such an unreliable connection does not provide proper bandwidth and causes instability in the electrical network, which leads to the failure of electrical equipment.

These shortcomings are deprived of the connection method using crimping (crimping) of wire lugs. To do this, use a special tool - crimpers (crimps), which provide tight and high-quality contact.

Strictly speaking, wire crimping is about the same as in other areas of activity.
Creating the tightest possible connection by applying mechanical force.
Creation (if possible) of an inextricable connection that can withstand significant physical loads on the break.
The ability to ensure the continuity of the flow (we have current) at the most difficult conditions operation.
Installation speed without loss of connection quality.

We will proceed from this, because we often need the crimping of cable lugs, although we do not know anything about this. Although it seems simple:

Here we put the cable into such a little thing with a handle, we will properly squeeze the sides of the entrance, and it will be possible to screw this thing anywhere. By the way, such sleeves for crimping wires are sold anywhere, so you can buy them very inexpensively. Like a tool, because the lugs for wires for crimping with your own hands and pliers cannot be crimped.

So, for a one-time job, this will not be the most budget solution. Especially if you do not understand how crimping wires compares favorably with other cable methods.

First of all, wire crimping only applies to multicore cables. This should be borne in mind, since a reliable connection of one core, even with the most powerful mechanical loads, cannot be obtained.

The second is very important point. The number of cores matters, but the diameter of the cable does not. That is why the thinnest cables are crimped, the crimping forces of which are minimal.

And third. Crimping cable lugs is not possible without a special tool that is designed to perform this procedure.

And most importantly. What do we get as a result of pressing? We actually get cold welding» with the help of mechanical force of all cores of a crimped cable with a lug, without the use of soldering or other temperature effects.

This is the meaning of crimping wires - creating a strong connection quickly and without using the reliable switching method familiar to an electrician.

We just press the cable into the ferrule so hard that the connection becomes permanent. Well, the speed of installation, of course, is a significant factor for connections in electrical wiring. Even in crimping, there are limits to the applied force, so do not push the cable and lug too hard. Everything needs a measure.

Soldering a stranded wire is not the easiest operation, because you need to expose all the wires, make sure that they are clean in terms of contact, and only then proceed to soldering. Any core in a stranded wire has insulation, and this often creates difficulties in establishing reliable contact.

Just crimping the cable lugs solves all these problems, because with the help of mechanical force (compression), not only the insulation of individual cores is destroyed, but also a strong connection of the entire cable is created for better contact.

The problem is that the size of these sleeves is small, and the markings are incomprehensible to those who are not specialists. But before that, let's define the difference between a sleeve and a cable crimping lug.

These are typical sleeves:

With its help, you can "lengthen" the cable, both the same section and different.

And this is a typical tip:

And just in both photos it is clearly seen that there is practically no place for full marking, unlike such sleeves and tips:

Therefore, there can be only one recommendation - well-marked products will cost more, while unmarked ones are no worse. You just need to consult with the seller, as a rule, they are well versed in this issue.

ring tips (NKI);
fork tips (NVI);
pin round tips (NShKI);
flat (plug) connectors (RPI-P, RPI-M, RSHI-P, RSHI-M, etc.);
piercing type couplers (OV).

Here it is necessary to return to the tool that provides crimping of wires, because each tool shows the dimensions for the standard shape of the jaws, and the force itself is accurately measured by diameters. So, if you didn’t make a mistake with the diameter, you won’t be able to apply excessive force.

And, despite the fact that the lugs for wires for crimping are different, with the same diameter and force, and the standard of the tool will be the same. It is a pity that this parameter is not reflected in the marking. Apparently because usually such work is done by professionals, not home electricians.

But it is precisely the standards that allow home electricians to stock up on universal crimping pliers and, without any problems, crimp cable lugs for their own purposes. It is quite simple to master this procedure, and technologically it is the same for crimping an RG-45 connector and a tip for a three-phase machine.

When crimping a multi-core cable, special lubricants are indispensable. Therefore, use sleeves and tips that already have this lubricant inside. In any case, this is a one-time operation. It will not work to remove the sleeve or tip in order to rearrange it to another place.

As a result, having mastered the installation of sleeves and tips, you will be able to quickly restore the desired connection, carry out repairs without problems, as well as a connection that, in fact, will not need repair for many years.

For every inhabitant, a striking example of improper 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.

Sleeves and tips are intended to remove or minimize the contact resistance, in other words, to eliminate poor-quality contact, for a bolt or screw.

High-quality contact in the connection, contact resistance:

For crimping (crimping for lugs) of wires and cables, special products are used - lugs and sleeves. Tips can be for stranded wires and solid wire, they are divided according to the purpose and type of wire for which they are used (copper or aluminum).

copper tube

with different diameters under the wire and the mounting hole, which does not have a protective coating;
for crimping electrolytic tinned with different holes for fastening.

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.

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 contact resistance.

Quite often in electrical engineering there is a connection of an aluminum wire with a copper cable, in this case it is recommended to use aluminum-copper lugs for high-quality connection of an aluminum wire and a 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.

Wire crimp - types

cylindrical shape;
forklifts;
loop;
connecting;
knife.

In addition, the crimping range is important, which shows the maximum and minimum cable cross-section. When working with wires with a diameter of 0.25 to 16 mm, use manual press tongs. They are suitable for laying and repairing computer networks, telephone lines and other low current systems.

The crimping of car battery wires, cable lugs with a diameter of not more than 120 mm and the installation of substations are performed using a hydraulically driven tool.

For large volumes, it is advisable to use electric pliers, which can operate in automatic or semi-automatic mode.

Additional insulation. Usually, plastic is used to make tick handles, but some models also have rubber inserts. It does not conduct electricity and reduces the risk of electric shock.
Blade on the working part of the tool. It allows you to cut the cable and do without additional equipment.
If it is necessary to carry out crimping of sleeves of different sizes in in large numbers, then it is better to choose pliers with rotary dies or an adjustable punch.
Due to the design features, they can be used to work with wires of different sections. No crimping large diameter carried out with the help of pliers with curly sponges.

For crimping insulated and non-insulated insulated tips, in order to fix them at the ends of wires of various sections, apply manual press tongs called crimpers. Crimpers are professional tools for electrical installation, and are produced by many manufacturers of hand tools.

With the help of pressing tongs, you can crimp the tips various types: ring, fork, pin, plug, sleeve and flat connectors, connector sleeves and other types of lugs.

The jaws of the mites are called the matrix, there are recesses on it special form for different diameters of crimped wires, flexible stranded and solid single-wire, and, accordingly, for various lugs.

Insulated lugs are suitable for stranded wires, bare lugs are suitable for single-wire rigid ones.

Tips as such are a convenient means of reliably connecting sockets, circuit breakers, UZO, lamps, switches, chandeliers, counters and many other devices.

For crimping conductors of a significant cross section, more than 16 square millimeters, hydraulic presses are used, but for the needs of professional electrical installation, manual press tongs and crimpers are also suitable.

Press tongs (crimpers) are different. There are specialized crimpers, for example, for crimping only 4P4C and 4P2C telephone jacks, as well as multifunctional ones, combining, for example, a stripper - a stripping tool. There are crimpers for fiber optic connectors, for D-sub connectors, etc.

A typical crimping crimper has comfortable plastic handles and a steel body and jaws. Such a device allows you to crimp the tip with one hand.

Particularly convenient are crimpers with a ratchet mechanism that blocks the opening until the end of the crimping of the tip is completed, so that undercrimping does not occur. If the crimping needs to be interrupted due to, for example, an error in the wire or ferrule diameter, the ratchet can be released manually.

Crimps often located on the jaws are marked different colors, for example, a crimp for a wire with a cross section of 0.25 to 1.5 sq. mm is marked in red, from 1.5 to 2.5 sq. mm in blue, from 4 to 6 sq. mm in yellow.

This is necessary so as not to get confused and not make a mistake with the diameter of the wire and with the tip. By the way, the insulated tips themselves also have colored cuffs of the corresponding colors.

The pressing process is quite simple. For example, you need to crimp the wire PuGV 1x4.0 sq. mm. To do this, take the necessary tip, for example, we need an annular one, and we chose NKI 6.0-4, which is suitable for wires with a cross section of 4 to 6 sq. mm.

First, the insulation is removed from the wire for the length of the tubular part of the tip to get the contact part, the strands of the wire are twisted a little, the tip is put on so that the wire protrudes slightly (about 1 mm) beyond the cuff, and the insulation rests against the metal.

The tip is installed in a matrix of press tongs, in our case - in yellow, and the crimp is carried out, holding the wire. There is an indentation along the profile of the tip into the wire. Then check the strength of the obtained crimping.

With the help of press tongs, you can crimp various connectors, crimp a variety of wires, and select any necessary lugs.

Among the extensive range of crimpers on the market today, every professional installer will easily select a tool for his profile. It can be a simple crimper or crimper stripper, multifunctional, or for only one type of connector, such as RJ45.

Crimping pliers for automotive terminals

Crimping pliers for auto wire terminals are an auto tool, thanks to which the wires inside the sleeve are well spliced and the cable is connected to the lug. The use of this tool in a car workshop significantly increases the speed and quality of work on repairing the electrical wiring of your car or your client.

Moreover, this tool is not limited to professional equipment, and therefore can be used for private car repairs in the garage.

Pliers for crimping automotive terminals are divided into 2 varieties: diaphragm or functioning like ordinary pliers. The latter squeeze parts from 2 sides.

They have special holes on the jaws that allow you to correctly guide and adjust the repaired parts. These tools are considered universal, since they can be used to get to problem areas from different sides and projections.

Diaphragm crimping pliers adjust elements on 4 or 6 sides. More precise instrumentation properties depend on aperture functions. This mechanism provides a very tight cable crimp.

In addition, due to the features of the equipment, it can adapt to sleeves of different sizes, which ensures its versatility.

But diaphragm crimping pliers have a certain disadvantage. They can only be used if the wires are inserted into the sleeve from one side. Otherwise, the pliers will be on the wire due to the structural features of their head.

The hydraulic manual press is designed for crimping cable lugs and sleeves with a hexagon, with a cross section of up to 70 mm². Copper lugs and sleeves must not exceed a cross-sectional area of 50 mm².

Does the design have a pressure relief valve. Such products are more reliable, they prevent overloading the press from pressure.
Type of pressing head, which can be open and closed type.

pre-open the stopper;
pull out the matrix;
put the wires and tip;
close the device.

And only after that you can start crimping the cable. For wires of small cross sections, the process is much simpler. If the press has an open type C-head, the wires can be pressed quickly anywhere.

Up to 70 mm².
Up to 120 mm².
Up to 300 mm².
Up to 400 mm².

With an increase in the power of the press, its mass increases. Some manufacturers reduce weight by using light aluminum alloys for the housing. All hydraulic presses are designed for crimping copper and aluminum wires.

Complete with a press there are replaceable dies for crimping. Most modern models, are equipped with rotating heads and fast travel device.

Inside the device, on the one hand, there is a working piston with a cuff - a spring is mounted to return it to its original position. On the other side, a pressure cylinder and a plunger are installed.

The main components of a manual handpiece press

Pos. 1 - axis.
Pos. 2 - head.
Pos. 3 - matrix half-forms.
Pos. 4 - screw.
Pos. 5 and 6 - handles.

The pump plunger reciprocates.
The cylinder is pressurized.
Oil under pressure begins to flow into the working cylinder, moving the working piston.
The piston, acting on the matrix, creates the right pressure on the tip.
The design has a two-way plunger.
At idle, the circuit that provides rapid injection of fluid into the working cylinder is open. At the end of idling, the second circuit begins to open, developing maximum effort.
The return spring, with the shut-off valve open, which connects the working cavity of the cylinder and the oil cylinder through the channels, returns the piston to its original position.
The crimping press for cable lugs is equipped with safety valve, which, when the pressure in the system is exceeded, begins to bypass a certain amount of oil back into the oil bottle.

Handpiece manufacturing

What to do if you don’t have special crimping tools at hand or just don’t want to buy them if you only need to crimp one or two tips?

Many faced with this problem resort to wrong ways, which further only worsen the contact, not providing a reliable connection.

They begin to flatten the tip with hammers, simply squeeze it in a bench vise, crush it with pliers, and press it in with a chisel. All these methods are not correct and do not bring the desired result. After such amateur performance, poor contact is obtained with its further heating during operation.

True, some manage to compress the tip with a hydraulic press so that the wire quietly crawls out of it, it is worth pulling with a little effort.

There are other ways to crimp power wires with tips using improvised tools that can be found in almost everyone in a garage or at home.

The easiest and fastest way is to press in with a center punch.

ordinary hammer;
the tip itself, no matter what type and manufacturer;
vice or sledgehammer;
a center punch or, in extreme cases, a 200mm nail can be used once.

insert the tip into the wire;
put it on a hard surface - an anvil, vise, wide side of a sledgehammer;
and with uniform blows of the hammer on the center punch make point dents on the tip. First on one side, then on the other.

In this case, it is not necessary, as many do, to pre-flatten the tip with a hammer. In the process of strikes, this will happen anyway.
The number of cores, that is, holes from impact on the metal, depends on the length of the tip.

At the same time, on the reverse side of the tip, the crimping points should not be symmetrical with those on the front, but shifted by a couple of millimeters.

The most important thing is not to make a hole through the tip and control the impact force. Therefore, if you use a 200mm nail for this, you should first of all blunt it.

As a result, you will get sufficient contact, which, of course, cannot be compared with crimping with a professional PGR-70 tool, but in the absence of super-rated loads, it will last a long time. The most important thing in this method is to choose the right wires and tips. The declared cross section is very often less than the actual one.

For reliable contact, the wire must fit snugly inside the sleeve without any slack. So this moment always checked manually, do not blindly trust the numbers on the cable sheath and on the tip blade.

There are others simple ways connecting lugs to wires without using a press. For radio amateurs who do not have problems with solders and other devices, ordinary soldering is suitable.

This is not exactly a crimp, but it is still a connection method without the use of a special crimping tool.

The wire is tinned, the tip inside too. At the same time, in its upper part, where the blade is, a small hole must be drilled in the sleeve.
The stripped end of the cable is brought in, after which the entire structure (cable + tip) is wrapped with fiberglass tape.
It is heated by a gas burner and molten tin begins to be poured into the hole from above.
With constant heating with a burner, it will easily penetrate between the wire strands and the walls of the sleeve. The fiberglass will prevent the tin from flowing out.

Some do it even easier. They put tin inside the tip, heat the whole thing with a burner or even on gas stove and then insert the tinned cable there.

In order not to damage the insulation at the end of the wire, you can use a building hair dryer to warm up:

If you do not have soldering accessories, and you consider crimping with a dot using a center punch not reliable enough, then the third method remains.

Pick up a long enough threaded screw so that it overlaps the pressed part of the sleeve. The diameter of the screw should not be large, so as not to push through and crush the tip itself.

Position this screw along the tip. Then you compress the entire structure in a vice. As a result, you should get something like this form of pressing.

If one screw is not enough, a second one is superimposed over the depressed one and compressed again. You can initially use 2 screws, only installed on different sides of the sleeve. The main thing is not to overdo it and not break the sleeve.

To prevent the screw from moving, it can be fixed with electrical tape. In general, summing up, we can say that these three methods have the right to life, and many only connect wires this way power cable and tips.

When working with wires for various purposes, it constantly becomes necessary to connect them to electronics or other household appliances. To perform this task, it is customary to use a 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. On cost crimping tool usually several factors can influence - 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 type of wire) or a wider one (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 can be suitable for working with stranded electrical network wires: 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 the press end sleeves. 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 cable lugs. 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.

When using such tongs when working with insulated wires, 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. Open end press pliers, which are made of brass, may have certain types 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 certain kind 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, the device should be placed in the seat of the ticks. Be sure to check the consistency of the colors of all cores. When they are in the correct position, you can press. 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.

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

A rectangular bag made of dense fabric, apparently two pieces of cardboard inside give shape. 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. The metal base goes to the end of the plastic handle - the magnet sticks to the end of the handles too.

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 types of ring non-insulated 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.
In different countries, there are 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 stranded wire terminals.
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.

Minuses

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.

All the best and good contacts in the right places!

The product was provided for writing a review by the store. The review is published in accordance with clause 18 of the Site Rules.

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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 tips or sleeves that have a different look and purpose. 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 improper wiring is the stair switchboard, many apartment owners have melted wires in the switchboard, there are twists. Crimping lugs can save citizens from the possibility of heating and igniting 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 eliminate poor-quality contact, for a bolt or screw.

For crimping the copper conductors of the cable, lugs are used, made of a solid-drawn 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 a 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.

With a decrease in the overall dimensions of 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 lug, 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. To crimp the lugs, a tool is necessary, 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 brand PK2 or PK2M are hand tool, which is used in the termination of conductors 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 a cable lug, there is also a sleeve ending, its choice is made according to the type of wire being connected (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, the GAO brand is selected: an aluminum sleeve of a 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 the 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 allow the use of products of large diameter for terminating 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.

Professional handpiece pressing pliers are presented in the form of a mechanical tool that allows you to ensure a reliable connection of two elements. Outwardly, their design most of all resembles ordinary pliers, but instead of even sponges, specific relief matrices are used. Their functionality is designed for different forms and crimp diameters.

Short description

Long term operation electrical networks largely depends on how well all the connections between the conductors were made. That is why crimping products are widely used, with which you can achieve the most reliable connections non-detachable type. During this procedure, the cores of the prepared wires are carefully compressed in special sleeves made of aluminum or copper. In order for the result to be of high quality, the master must apply a large compressive force provided by crimping tongs.

Such a tool is often called a crimper, since many manufacturers equip the unit with interchangeable dies with profiles that are combined with both conductors and insulation. On sale you can find quite large sets of such devices, where each master will find everything necessary for high-quality work.

Most often, modern professionals use a mechanically driven crimping tool. Such units are equally effective in both industrial and domestic industries. Of course, if necessary, more powerful pressing tongs can be purchased, where the main work is performed by a hydraulic drive. They can be used to process cables with large diameter and cross-sectional area from 120 mm².

Universal press pliers for crimping sleeves and tips consist of two basic parts:

The fixed element is a matrix, which is presented in the form of a curly bracket, providing the necessary deformation of the material.
The moving part is a specific punch, without which high-quality extrusion on the sleeve cannot occur.

Matrices are selected in strict accordance with the diameter of the tip. Depending on the model used, all adjustments occur through fine adjustment or replacement of the part itself. Standard domestic installation of such a tool is made in the form of non-removable curly sponges, which are designed for quick crimping of different-caliber sleeves.

AT removable models ticks are of great importance right choice working area, which necessarily includes a matrix, as well as a punch. If the master made some mistake, then the final connection will turn out to be extremely low, and normal contact will simply be unavailable. In addition, the compressive force must also be able to measure. After all, excessive pressure will tear the sleeve, which will make it unsuitable for further operation. But a weak crimp, on the contrary, will not be able to provide high-quality contact, the final contact will be extremely unreliable.

It should be noted that recently the craftsmen have been actively using manual press tongs of the PK-16 brand, which are manufactured by the KBT company. The thing is that such devices have the simplest design, a high degree of endurance, and they are also very convenient to use. The tool completely lacks unnecessary auxiliary functions, due to which it is included in the list of the most popular budget options.

Applications

Crimping pliers are actively used by both beginners and more experienced radio amateurs, as well as electricians and auto mechanics. Such units are simply indispensable in situations where you need to process the contacts of standard cables and professional connectors with an unusual connector (this category includes a network cable for a PC).

Light and simple design such crimpers gives each master the opportunity to complete the task as quickly and efficiently as possible. The device is guaranteed to provide reliable and tight crimping of the workpiece, due to which the highest degree of contact between the connecting element and the conductor is achieved. The price of the unit directly depends on the manufacturer, the type of design and quality.

It is worth noting that crimping pliers do an excellent job of crimping insulated wires:

NShKI - pin round tips.
GSI - connecting sleeves.
NCI - ring type tips.
RPI-P, RSHI-P, RPI-M, RSHI-M - flat and plug connectors.
OV - piercing type couplers.

Crimping units are actively used for flexible conductors of wires in the process of connecting circuit breakers, chandeliers, sockets and lamps. Professional crimping of connector sleeves in the industrial sector is carried out using universal pliers hydraulic type. Such units are designed for cable cores with a cross section of 16 to 240 square meters. mm.

Design differences

Universal pressing tongs are designed to work with sleeves and tips, the cross section of which can vary over a wide range. In the domestic and industrial sectors, the most common are parts with an indicator from 1.5 to 16 mm². The special design allows you to precisely press the metal of the tip (sleeve) into conductive wires conductor. The final result depends on the required depth and application profile.

Some models are equipped with a ratchet mechanism, due to which the handle of the unit is in a compressed state until the crimp is completed. At the final stage, the pawl is triggered and the inverter mode is turned off. In such a situation, the master simply will not be able to squeeze the handle, since the tool's jaws are not fully open. In addition, the unit can be equipped with a side swivel wheel that disables the lock if necessary.

Each tool jaw is equipped with working areas with a variety of profiles. Such technical solution allows craftsmen to crimp any type of lugs and sleeves with a standard section. For more comfortable work, each zone is marked with its own number or a special stamp, due to which errors associated with the wrong choice of size are prevented.

PK-16 products do not differ at all from their counterparts in any way. design features. But the presence of longer handles allows you to comfortably work for a long period of time without making much effort.

If the master decides to use the production area with numbers 1.5 and 6.0, then he will need a little onslaught of one hand to make the result as high quality as possible. But for zones 10 and 16 it is necessary to use the power of two hands. It is worth noting that if a specialist most often works with large tips and sleeves, then it is better for him to buy a more powerful and larger unit.

Varieties of pressing units

Many modern manufacturers engaged in the manufacture of crimping pliers based on various standards. The buyer can always buy available tool with a narrow scope (pressing a certain type of cable) or universal models. That is why even before buying it is necessary to determine what work the unit will perform.

Rules for using the tool

Despite the fact that many novice craftsmen consider crimping quite simple view work, but even in this case there are specifications on which the quality of this procedure depends. The correct choice of the unit is of great importance, since it must have an optimal compression force, which will be quite sufficient for the sleeve used.

Between those wires that are interconnected due to crimping, the most high-quality and reliable contact is created. In order for the result to meet all the requirements, certain rules must be followed:

Larger sleeves with a section of 10 or 16 mm² can only be crimped at certain intervals. Otherwise, frequent exposure to excessive loads can deform the tool, due to which it will become unsuitable for further use.

Main advantages

Many people think that crimping pliers are not needed at all to connect lugs and wires of a small cross section, because they can be replaced with ordinary pliers. Of course, such a way out of the situation is quite accessible, but it will no longer be possible to achieve such high quality as with ticks. And all because the matrices of the tongs provide a too tight fit of the tip to the core, which prevents the penetration of water and air. Due to this, metal oxidation can be excluded, which is especially important when working with copper parts.

During the use of pliers, gaps are formed where dust, moisture and any debris can easily enter. The quality of the contact will be reduced several times, and this is fraught with an increase in current resistance. The cores receive too much clamping, which violates their cross section. Over time, some of them will thin out or simply fall off, which will reduce the conductivity of the signal.