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BS7609 Crimping Cables With Cembre Cable Lugs & Crimping Tools https://www.powerandcables.com/crimping-cables-cembre-cable-lugs/

In addition to the requirements of BS7609, Cembre advises the following when crimping cables – it is important that the crimped cable installation is not compromised by a poor choice of copper tube lug, or by the use of a ‘mismatched’ crimping system:

Cembre supports the Approved Cables Initiative (ACI) Code of Practice to ensure that the conductor used is both third-party approved and appropriately marked.
The cable lug should have an equal current carrying capacity to that of the conductor. Copper tube lugs designed and manufactured by Cembre achieve maximum electrical conductivity with minimum resistance by the use of high purity, electrolytic copper having a cross sectional area equivalent to that of the conductor.
Beware cable lugs are manufactured from thin wall copper tube as they have the potential to cause elevated temperatures when the conductor is carrying high levels of current.
Recommended procedures for conductor preparation and crimping Cembre copper tube lugs, including number, position and sequence where multiple compressions are required.
Cembre copper tube lugs are also fully annealed after pressing to alleviate residual stresses within the palm area and ensure optimum mechanical and electrical performance at the connection interface.
Ensure Cembre crimp tooling is certified as calibrated regularly and serviced correctly and all equipment, particularly die sets, is inspected for damage or wear and maintained in good condition.

Cembre Crimp Lug Correct Installation

Cable Crimping

Some best practise requirements:

Approved cable conductor correctly prepared

Conductor strip length = cable lug barrel length
Manufacturer and size shown on crimp lug
Cable lug and conductor have equal copper content
Crimp tool optimises performance of dies
Crimp dies matched to tool, lug type and size
Correct number, position and quality of crimps
Cable lug marked to check correct dies used

Choosing the correct Cembre die set:

ALWAYS refer to the Cembre die selection chart. A die selection guide booklet is also included with every new Cembre crimp tool, whether hydraulic crimping tools or battery crimping tools.

The number and sequences of compressions per cable lug:

The number and sequence of compressions shown in the die selection guides are specifically determined for Cembre lugs from the lug type and design, the force applied by Cembre crimp tooling and the bite width of the matched die set.
ALWAYS apply the correct number of compressions as per the die selection guide in order to assure the performance of the joint after cable crimping.
Apply each compression in the correct sequence to avoid distorting the cable lug.

Which Cable lug & die combination to use when crimping extra flexible conductors?

Cembre copper tube lugs for extra flexible conductors 35sqmm to 185sqmm have the same cross sectional area of copper as standard Cembre A-M lugs for LV applications, but with a slightly wider inner diameter to more easily accommodate the fine strands.
Above 185sqmm it may not be possible to use the correct size standard lug with an extra flexible conductor. For example, say a 240sqmm lug does not fit on a 240sqmm extra flexible conductor, it is acceptable and common practice to use the next larger size of lug, here 300sqmm.
The lug MUST however be crimped with the die set appropriate to its size, 300sqmm, since using a 240sqmm die set will distort the cable lug and be detrimental to performance.

Which Cable lug & die combination to use when crimping compacted conductors?

For low voltage applications use Cembre A-M Copper tube lugs. Matched crimp tooling and hexagonal die sets MUST be used.
Always apply the rule that the cross sectional area of the lug should at least equal that of the conductor so, when using compacted conductor it is essential that the correct size lug be used, even if the fit appears ‘loose’ prior to crimping.
The apparent ‘loose’ fit is due to the air between conductor strands having been ‘compacted out’ during manufacture, causing a slight reduction in the diameter of the conductor. The resulting gap between conductor and cable lug barrel wall is fully taken up during the crimping process.
Do not be tempted to move down a lug size to obtain a tighter fit, as there will then be insufficient copper in the shoulder or palm of the cable lug. As an example, for 185sqmm compacted conductor use A37 lug, ME37-C die set and appropriate Cembre crimping tool.

Cembre
T&D are Main UK Stockists for the Cembre range of compression connectors (cable crimp lugs and splices) for all low and high voltage crimping applications of power, control and instrumentation cables with either copper or aluminium conductors.

Cembre copper, aluminium and bimetallic cable lugs and splices are designed for high voltage cable crimping applications including 3.3kV, 6.6kV, 11kV and up to 33kV. Cembre 2A HV cable lugs and splices are made from high purity copper, annealed and tin plated with extended barrels for reliable high voltage electrical connections.

Cembre electrical connectors are the market leading crimping system for reliability, consistency and peace of mind performance – specify Cembre to crimp, splice and terminate your vital high voltage electrical circuits.

A Quality Comparison – Cembre v Unbranded Cable Lugs

Both of the below copper cable lugs in picture 1 are specified by their respective manufacturers to crimp and terminate 400sqmm stranded copper cables – pictured right is the Cembre cable lug, note the CE Marking. CE marked cable lugs guarantee product compliance with EU safety, health and environmental requirements. Clearly the Cembre lug has increased barrel length and a thicker cable lug wall for an
advanced standard of electrical connection with excellent conductivity due to high copper content – the thinner wall cable lug pictured alongside which is a imported and unbranded product is lighter weight and dimensionally smaller than Cembre brand lugs.

When terminating either armoured, unarmoured or braided cable types we recommend only to use branded type cable terminations such as Prysmian cable glands.

Quality – Cembre crimp lugs and splices are manufactured from electrolytic copper tube – the copper tube dimensions are designed to obtain the most efficient conductivity and mechanical strength to resist vibration and pull out. This includes electrical connectors for LV 600/1000V and MV HV cables operating at 11kV/33kV.

Strength – Cembre cable lugs are annealed to guarantee optimum ductility which is an absolute necessity for crimp connectors which must withstand the severe deformation arising when compressed by hydraulic crimp tools. In electrical installations subject to vibration, crimp terminals must perform a reliable connection – annealing avoids cracking or breaks between the cable lug palm and barrel. This applies
especially to Marine & Shipboard cables in offshore installations subject to high levels of movement and mechanical stress.

Reliability – Cembre cable lugs feature an extended barrel design facilitating full insertion of the the copper conductor into the crimp lug – the cable lug barrel length has been designed to allow easy and accurate positioning of the dies during the crimping operation.

Note the distinctive quality differentials between the Cembre brand transformer lugs and unknown, unbranded type.

1. Cable Lugs – Low Voltage Single Hole 400sqmm.

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BS7609 Crimping Cables With Cembre Cable Lugs & Crimping Tools https://www.powerandcables.com/crimping-cables-cembre-cable-lugs/

2. Transformer Cable Lugs – Cembre Brand

3. Transformer Cable Lugs – Unbranded

Further Reading

Crimping Aluminium Cables Using Cembre RHU131-C Presshead

Selecting & Positioning Dies In Cembre ECW-H3D Presshead Tool
Replacing Cembre Cable Cutting Tool Blades – Model TC055
Ensuring Optimum Performance Of Cembre Crimping Tool – Model HT131-C
Cembre B1350-CE v. B135-C Crimping Tools Performance Comparison

Thorne & Derrick – Stickists & Suppliers of MV HV Joints, Terminations & Connectors

Thorne & Derrick

T&D are Specialist Distributors of an extensive range of LV, MV & HV Jointing, Earthing, Substation & Electrical Eqpt – this includes 11kV/33kV/66kV cable joints, terminations and connectors for both UK DNO, private network applications and international cable specification and standards.

Contact our UK Power Team for competitive quotations, fast delivery from stock and technical support or training on all LV-HV products.

Key Product Categories: Duct Seals | Cable Cleats | Cable Glands | Electrical Safety | Arc Flash Protection | Cable Jointing Tools | Cable Pulling | Earthing | Feeder Pillars | Cable Joints LV | Joints & Terminations MV HV

3 of 5 28/11/2021, 12:42
BS7609 Crimping Cables With Cembre Cable Lugs & Crimping Tools https://www.powerandcables.com/crimping-cables-cembre-cable-lugs/

MV HV Cables 11kV 33kV – Joints, Terminations & Connections

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