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de Special 1-2/2008
ELECTROINSTALLATION:
Which cable
lug suits which
application? ORGAN DES
ZVEH
Electroinstallation AT A GLANCE
Cable lugs provide safe electrical
connections. We show which cable
lug suit which application and which
tool should be used.
O
n the German market
hundreds of different Incorrect tools or an
versions of cable unprofessional crimp can cause
lugs are available. For increased temperatures or
the electrician it is very even fire.
Source: Klauke
difficult to choose
from this broad range
the correct cable lug compression cable lugs DIN
for each specific app- 46235. Range of cross section is
lication. The following from 6 mm2 up to 1000 mm2,
article gives an overview bolt sizes range from 5 mm up to
of the different types of 20 mm. Electrolytic copper according
cable lugs for copper conductors to EN 13600 is mandatory. For corrosion
and details the facts which will protection, compression cable lugs –
guarantee a safe and long-lasting In addition, these cable lugs indicate also standard tubular cable lugs and
connection. the number of required crimps ( p i c- terminals – are tin plated.
t u re 2 ).
In principle we differentiate bet- Copper tube cable lugs
ween three types of cable lugs For installing, the DIN standard re- “standard design”
( p i c t u re 1 ) . commends crimping dies according to
DIN 48083, part1, 3 and 4 for solid, Apart from DIN cable lugs, many manu-
• Compression cable lugs according to stranded and fine stranded conductors. facturers also offer standard tubular
DIN 46235 For braided ropes the standard refers cable lugs, also made from electrolytic
• Standard tubular cable lugs to the information of the manufactu- copper according to EN 13600. As far as
• Sheet metal terminals according to rer. Klauke generally recommends the sizes are concerned, standard tubular
DIN 46234 use of hexagon crimping dies according cable lugs are mostly shorter than DIN
to DIN 48083, part 4 for installing of cable lugs and also differ in tube
Compression cable lugs according
to DIN 46235
Source: Klauke
case Klauke)
• 22: Die code (only for compression
cable lugs DIN 46235)
• 12: Metric bolt size for connecting Picture 2: Only DIN compression cable Picture 4: Standard tubular cable lugs
bolt: size M12 lugs show the required number of (left) have different tube dimensions
• 150: Cross section of conductor in mm2 crimps stipulated by the manufacturer. than DIN compression cable lugs (right)
2 de Special
Electroinstallation
Picture 5: Incorrect and correct crimps in comparison: An incorrect crimp (left:excess crimping, middle: low force crimping,
and usage of incorrect crimping tools can result in an increase in joint resistance and may jeopardise the installation;
right: correct crimping)
Source: Klauke
Source: Klauke
Source: Klauke
Picture 6: F-Cable lugs with flared
entry represent an option when Picture 7: The longer tube of Klauke Picture 8: High quality Klauke cable
cables of class 5 and 6 will not fit into cable lugs (above) guarantees a high lugs (above) show a clean and vertical
normal cable lugs. quality connection. tune end
dimensions ( p i c t u re 3 , 4 ). However, Sheet metal terminals are also made In practice it can happen that flexible
since these lugs are also subject to test from electrolytic copper according to class 5 and 6 cable conductors do not fit
standard IEC 1238 part 1, durability of EN 13600. But there is a difference in into the appropriate cable lug. For such
electrical and mechanical connection is the basic material. While compression cases Klauke recommends the so called
not affected. standard tubular cable lugs are pro- F-cable lugs which have a larger inner
duced from copper tubes, terminals diameter and feature a flared entry.
All cable lugs – irrespective of type – are made from copper sheets. Ter- Indent crimping is recommended
can only be crimped properly when minals show a soldered seam as the ( p i c t u re 6 ) .
a suitable tool is used. Incorrect tools DIN standard prescribes a closed tube.
or an unprofessional crimp can result The DIN standard does not specify For installing the DIN cable lugs,
in increased joint resistance, increased crimping tools – Klauke recommends crimping tools with die codes according
temperatures and even fire. ( p i c t u re their self-designed indent crimping to DIN 48083 part 4 have to be used.
5 ). To exclude such consequences tools. For tubular cable lugs please refer
Klauke recommends for crimping of to the tool recommendations of the
their cable lugs the exclusive use of Useful information manufacturer.
their appropriate crimping tools.
The selection of the correct cable lug Electrical and mechanical
Sheet metal terminals according very much depends on the cable type. properties
to DIN 46234 For cables according to DIN 57295 the
following cable lugs can be used. The International Standard IEC 1238
Also for the sheet metal terminals • Cables class 1, 2, 5 and 6: Compression part 1 applies to electrical and
certain standards apply regarding cable lugs DIN 46235 mechanical properties of cable lugs.
application, dimensions and marking. • Cables class 2: Standard tubular cable The requirments for a permanent and
Other than compression cable lugs DIN lugs safe electrical connection for the
46235 terminals are designed only for • Cables class 2, 5 and 6: Terminals intended application are detailed in
crimping of stranded, fine and very fine this standard. Both a mechanical
stranded conductors – not for solid pullout test and an electrical durability
conductors. MORE INFO: test are defined. A test cycle simulates
the application in practice: The con-
Cross section ranges from 0.5 mm2 For more literature on these nection is being heated 1000 times
up to 240 mm2, bolt sizes from 2 mm subjects please got to up to 120° C, to imitate the morning
to 16 mm. Among others terminals voltage peak in the public power
http://www.vde-
they can be found in electrical control supply system. Also high current tests
verlag.de/engl.html
cabinets and vehicles of public trans- are being carried out at temperatures
portation services. of 250° C.
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The responsibility of adherence to these safety
rules lies with every manufacturer of cable lugs. For
this reason the manufacturers specify the
appropriate cable type to be used with their cable
lugs.
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