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Electroinstallation www.de-online.

info

Picture 9: When used in the


ground cast-resin joints protect
the connections against moisture.
It is important to consider that the
All in one. One for all.

Source: Klauke
connection is not subject to Hüthig & Pflaum Verlag GmbH & Co.
bending to avoid the risk of frac- Engineers professional tool-bag Fachliteratur KG
ture. Der Elektro- und Gebäudetechniker Lazarettstraße 4, 80636 München

The procedure for the copper sec- Advice: When using crimp connec-
tion is absolutely identical as on copper tions in the ground it should be strictly
compression cable lugs. The crimping observed that the connecting joints
marks on the product give detailed should be protected against moisture. de Special 22/2008
information as to origin and applica- ( P i c t u re 9 ). For this application Klauke
tion of the Al/Cu compression joints. recommends use of cast-resin joints. MEHR INFOS The quality bag comes with genuine
The marking “KL14 50 rm/70 re/se” sig- Klauke tools.
nifies For the application of Al/Cu com- Contribution on this issue
pression joints and cable lugs the fol- http://www.de-online.info/archiv/
2008/01-02/index.php?Page=
• KL: Manufacturer (in this case lowing should also be considered:
elektroinstallation04.html
Klauke) These products should not be exposed • Which cable lug for which appli-
• 14: Die code to bending stresses which could frac- cation?, “de” 1-2/2008, S.33
• 50: Cross section of designed ture the contact point. Application on http://www.de-online.info/archiv/
conductor in mm2 overhead lines is therefore excluded. 2008/08/index.php?Page=
• rm/sm: for round stranded and elektroinstallation02.html
KL390IS (6-pieces) KL130PM1IS KL130PM2IS
sector stranded conductors • Cable lugs for special applications,
Preview: Crimp profiles
• 70: cross section of solid conductor “de” 8/2008, S.27
at a glance http://www.de-online.info/archiv/
in mm2
2008/17/index.php?Page=
• re/se: for round solid and sector solid With a further feature story in one of elektroinstallation02.html
conductors the next issues of “de” we close the • Best Practise for Installation of
series on cable lugs and connectors. Aluminium Connectors, „de“

BRDESONDER222008GB 10.000 02/09 I


The marks on the copper section This article will deal with the various 17/2008, S.26 KL044200IS KL050205IS KL020165IS

also indicate the correct procedure. The crimp profiles which correct selection
standard suggests crimping dies acc. to depends very much on materials and Book on this issue
DIN 48083 part 1, 3 and 4 for solid-, fine cable types used. Schmolke, Herbert: Selection and
design of cables and conductors
and fine stranded conductors; for
2007.2, revised and extended edition.
braided round wires the standard 120 pages, paperback, with CD Rom,
refers to specifications of the manufac- 18€,
turer. Generally Klauke recommends Lutz Remmel, Product Manager ISBN 978-3-8101-0263-8,
KL745HK KL710 KL403
using hexagon crimping dies acc. to DIN Electrical connecting systems, www.de-online.info/ shop/
48083 part 4 for processing the copper Gustav Klauke GmbH fachbuecher/schmolke_kabel.html
section of their compression joints. www.klauke.com

The ideal companion for electricians, fitters or installation engineers:


The Klauke Engineers professional tool-bag has space for the complete
tool range and provides safe storage of laptop, documents, mobile phone or
business cards. The clever compartmentation as well as removable single
components turn the tool-bag into a very flexible system meeting all
day-to-day requirements.

For more information please visit www.klauke.com


ELECTROINSTALLATION:

Accurately
connecting copper
and aluminium ORGAN DES
5 de Special ZVEH
Electroinstallation IN BRIEF Electroinstallation
Copper and Aluminium conductors
are difficult to connect to each other.
It is therefore necessary to avoid the
ingress of moisture at all costs. For

Accurately connecting these applications special cable lugs


are needed and accurate operating
procedures should be adhered to.
minium / copper compression cable lugs
are the same as those for pure alu-
minium versions.
tions. Marking “16 KL25 150 rm/sm 185
re/se” stands for
recommended to use hexagon crimp-
ing dies acc. to DIN 48083 part 4. In
order to ensure an accurate and profes-
mend using the manufacturers crimp-
ing tools to crimp their cable lugs.
should be used, Klauke manufactures
aluminium dies in a silver colour
while dies for copper are yellow-gold

copper and aluminium Quality products manufactured by


• 16: Metric bolt size for connecting
bolt – size M16.
sional crimp avoiding over or under
compression is the use of appropriate
For instance the special crimping
dies for aluminium have a crimp width
coloured.

market leaders such as Klauke feature a • KL: Manufacturer crimping tools. Poor crimps can result in of 7 mm, i.e. 2 mm wider than the Connecting compound for alumi-
Copper due to its outstanding electrical properties are always consistent material thickness, exact (in this case Klauke) an increase in joint resistance and tem- crimping dies for copper cable lugs and nium connecting material
the first choice when selecting a conductor for an electrical diameters and correct fit are a prereq- • 25: Die code peratures that can lead to fires. To pre- connectors. This, however, only applies
uisite for ensuring high safety stan- • 150: Cross section of conductor vent such issues Klauke solely recom- to 60 kN crimping dies. The reason for All cable lugs and connectors for alu-
connection. A practicable alternative in many cases is aluminium
dards are always met. Like aluminium in mm2 this is that dies with a larger crimp minium conductors come with a special
particularly because of its low weight and easy application. In compression cable lugs conforming to • rm/sm: for round multi-stranded and width are able to connect a wider con- compound ( s e e p i c t u re 6 ). This aggra-
practice however the electrician can find it challenging to connect DIN 46239, aluminium/copper compres- sector stranded conductors ductor surface area with the cable lugs vates the non-conductive oxide layer

Source: Klauke
both these materials in a professional manner. sion cable lugs feature a barrier design • 185: Cross section of conductor and balance the poor conductivity of which is quickly formed on the surface.
allowing the use of oil soaked and in mm2 aluminium. To easily identify which die This compound improves the contact
paper insulated cables which prevents • re/se: for round single stranded solid properties and enables a perfect elec-
oil leakage. Picture 3: A professional connection and single sector solid conductors trical connection, and also prevents fur-
of an aluminium conductor with a ther oxygen penetrating the contact
Aluminium conductors copper busbar is done by means of The die code also needs special con- re – round solid conductor joints where further oxidation could

A
copper-aluminium connection at a glance an aluminium cable lug and a copper sideration. For an accurate and safe take place. To maintain the functional
is used for instance in an indus- Picture 2: The construction of Al/Cu palm. crimp the die reference should be the capability of the compound all leading
trial estate where local business cable lugs prevents any gaps which Aluminium conductors are available in same as that shown on the cable lug. Source: Klauke brand cable lugs are sealed with a plas-
use copper supply cables which are would allow the accumulation of four different versions which require in These abbreviations will be found The die code can be seen on the die Picture 5: The markings on the cable lug provide tic plug to prevent the compound from

Source: Klauke
then fed off an aluminium ring main. liquid to take place which would start some cases special processing. These next to other markings on all Al/Cu face as a mirror image so that after information relating to the crimps, the manu- drying-out and leakage.
But also in electrical substations it is the oxidation process. are ( s e e p i c t u re 4 ). compression cable lugs and identify compression the die code is visible on facturer, cross section and allocation of cable.
necessary to connect aluminium con- which conductors will suit the appropri- the cable lug for final control and se – sector solid conductor
Al/Cu Connectors
ductors to copper bus bars. The main • round solid conductor(re) ate cable lug. ( s e e p i c t u re 5 ). inspection.
problem here is that connecting alu- • sector solid conductor(se) For a correct connection of aluminium
minium and copper is not straight- very resistant oxide layer being formed. • round stranded conductor (rm) Markings on the product provide For an accurate processing of Al/Cu and copper conductors leading manu-
forward. To ensure a safe and correct (oxide barrier) • sector stranded conductor (sm) the installer with essential informa- compression cable lugs it is generally facturers such as Klauke offer reduction
connection the use of special alu- that no moisture can enter the connec- compression joints with a cross section
minium/copper cable lugs and connec- When metals are connected to those tions. In an environment where mois- range from 10 mm2 up to 300 mm2.
rm – round stranded conductor
tors are essential. ( P i c t u re 1 ). with a higher electrical potential such ture is present the contact points ( s e e p i c t u re 7 ). These products serve
as copper in the presences of an elec- between the copper and aluminium mainly the reconstruction of power
Aluminium-Copper: trolyte (condensed water) will result in need to be protected by using accurate lines, i.e. non-tension connections of
A problematic connection an electrochemical reaction taking operating procedures. ( s e e p i c t u re 2 ). aluminium conductors acc. to DIN EN
Greenlee CSJ-100 open jaw meter

Source: Klauke
place. During this process the differ- Primarily this requires the use of alu- 60228 resp. aluminium wires acc. to DIN

Source: Klauke
Generally aluminium is a reactive mate- ences caused in electrochemical poten- minium/copper cable lugs and connec- EN 50182 with copper cables acc. to DIN
rial that oxidizes easily, but in practice it tial can have a significant impact. tors. Due to the design of these lugs Non-contact voltage detection in the narrowest spaces – 48201, part 1 and copper conductors
sm – sector stranded conductor
has proved to offer good corrosion areas where moisture could accumu- the Greenlee CSJ-100 digital open jaw meter makes it Picture 6: High quality aluminium cable acc. to DIN EN 60228. These compres-
resistance. This characteristic is due to a An electrical circuit is generated by late and where the oxidation process possible. Picture 4: lugs come with a special compound which sion joints consist of interconnected
chemical reaction that takes place the copper electrode (anode), the elec- could start have been avoided. For this Various shapes improves the contact properties and ensures aluminium (E-Al) and copper parts (acc.
when in contact with atmospheric oxy- trolyte (water) and the aluminium elec- reason aluminium/copper cable lugs It is designed for AC current measurements of up to of aluminium a perfect electrical connection. to EN 13600).
gen resulting in a very thin but also trode (cathode). The voltage generated and connectors are specified for the use 200 A AC and for AC and DC voltages up to 1000 V. It conductors
in this copper and aluminium circuit in off-shore wind power stations. meets the requirements of safety category IV up to 600 V or Normally the aluminium part of
“semi metallic” state results in a short category III up to 1000 V. the cross section has a much larger
circuit. Aluminium/copper compression diameter ( s e e p i c t u re 8 ) to compen-
cable lugs Additional product features are the data-hold-function sate for the poor conductivity of alu-
As a result of the current generated Picture 7: Aluminium and copper minium. As with the cable lugs here too
for recording measurements, the automatic power-off
the Aluminium surface breaks down Leading manufacturers of high quality conductors with different cross plastic plugs are used to prevent
for longer battery life, an audible continuity check and a
causing the metal to electrolytically compression cable lugs for connecting sections are being connected drying-out and leakage. Important:
diode test.

Source: Klauke
decompose. This destructive process is aluminium connectors with copper bus using reduction sleeves. The use of Al/Cu compression joints
visible as a kind of blooming oxidation bars ( s e e p i c t u re 3 ) consist of an elec- requires that the correct processing
Source: Klauke

and begins already with the existence trolytic aluminium (E-Al) compression guidelines for copper and aluminium
of tiny copper particles on the alu- and are joined to a copper palm (to EN are observed.
minium; this ongoing reaction itself 13600).
does not cause the copper to corrode. Consequently the aluminium section
In an electrical connection however the The available cross sections range needs to be crimped like an aluminium
Picture 1: Use of an incorrect crim- resistance is increased leading to from 16 mm2 up to 400 mm2. The field Picture 8: Normally the aluminium compression cable lug (see above).
ping die and/or an incorrect crimp increased temperatures which then in of application covers in principle all section (right) has a larger diameter Characteristically for Al/Cu compression
will result in an over compression the worst case lead to a fire. non-tension connections of aluminium than the copper section (left) to equalize joints are the different crimping marks
(right) or an under compression cables acc. to DIN 48201, part 1, and the poor conductivity of aluminium. which are 7 mm on the aluminium sec-

Source: Klauke
(left) and in the worst case in fire. Therefore when connecting copper aluminium ropes acc. to DIN 50182. www.klauke.com tion and 5 mm on the copper part for
and aluminium it is important to ensure Specifications and processing of alu- crimping dies up to 60 kN.

2 de Special 4 de Special
Electroinstallation IN BRIEF Electroinstallation
Copper and Aluminium conductors
are difficult to connect to each other.
It is therefore necessary to avoid the
ingress of moisture at all costs. For

Accurately connecting these applications special cable lugs


are needed and accurate operating
procedures should be adhered to.
minium / copper compression cable lugs
are the same as those for pure alu-
minium versions.
tions. Marking “16 KL25 150 rm/sm 185
re/se” stands for
recommended to use hexagon crimp-
ing dies acc. to DIN 48083 part 4. In
order to ensure an accurate and profes-
mend using the manufacturers crimp-
ing tools to crimp their cable lugs.
should be used, Klauke manufactures
aluminium dies in a silver colour
while dies for copper are yellow-gold

copper and aluminium Quality products manufactured by


• 16: Metric bolt size for connecting
bolt – size M16.
sional crimp avoiding over or under
compression is the use of appropriate
For instance the special crimping
dies for aluminium have a crimp width
coloured.

market leaders such as Klauke feature a • KL: Manufacturer crimping tools. Poor crimps can result in of 7 mm, i.e. 2 mm wider than the Connecting compound for alumi-
Copper due to its outstanding electrical properties are always consistent material thickness, exact (in this case Klauke) an increase in joint resistance and tem- crimping dies for copper cable lugs and nium connecting material
the first choice when selecting a conductor for an electrical diameters and correct fit are a prereq- • 25: Die code peratures that can lead to fires. To pre- connectors. This, however, only applies
uisite for ensuring high safety stan- • 150: Cross section of conductor vent such issues Klauke solely recom- to 60 kN crimping dies. The reason for All cable lugs and connectors for alu-
connection. A practicable alternative in many cases is aluminium
dards are always met. Like aluminium in mm2 this is that dies with a larger crimp minium conductors come with a special
particularly because of its low weight and easy application. In compression cable lugs conforming to • rm/sm: for round multi-stranded and width are able to connect a wider con- compound ( s e e p i c t u re 6 ). This aggra-
practice however the electrician can find it challenging to connect DIN 46239, aluminium/copper compres- sector stranded conductors ductor surface area with the cable lugs vates the non-conductive oxide layer

Source: Klauke
both these materials in a professional manner. sion cable lugs feature a barrier design • 185: Cross section of conductor and balance the poor conductivity of which is quickly formed on the surface.
allowing the use of oil soaked and in mm2 aluminium. To easily identify which die This compound improves the contact
paper insulated cables which prevents • re/se: for round single stranded solid properties and enables a perfect elec-
oil leakage. Picture 3: A professional connection and single sector solid conductors trical connection, and also prevents fur-
of an aluminium conductor with a ther oxygen penetrating the contact
Aluminium conductors copper busbar is done by means of The die code also needs special con- re – round solid conductor joints where further oxidation could

A
copper-aluminium connection at a glance an aluminium cable lug and a copper sideration. For an accurate and safe take place. To maintain the functional
is used for instance in an indus- Picture 2: The construction of Al/Cu palm. crimp the die reference should be the capability of the compound all leading
trial estate where local business cable lugs prevents any gaps which Aluminium conductors are available in same as that shown on the cable lug. Source: Klauke brand cable lugs are sealed with a plas-
use copper supply cables which are would allow the accumulation of four different versions which require in These abbreviations will be found The die code can be seen on the die Picture 5: The markings on the cable lug provide tic plug to prevent the compound from

Source: Klauke
then fed off an aluminium ring main. liquid to take place which would start some cases special processing. These next to other markings on all Al/Cu face as a mirror image so that after information relating to the crimps, the manu- drying-out and leakage.
But also in electrical substations it is the oxidation process. are ( s e e p i c t u re 4 ). compression cable lugs and identify compression the die code is visible on facturer, cross section and allocation of cable.
necessary to connect aluminium con- which conductors will suit the appropri- the cable lug for final control and se – sector solid conductor
Al/Cu Connectors
ductors to copper bus bars. The main • round solid conductor(re) ate cable lug. ( s e e p i c t u re 5 ). inspection.
problem here is that connecting alu- • sector solid conductor(se) For a correct connection of aluminium
minium and copper is not straight- very resistant oxide layer being formed. • round stranded conductor (rm) Markings on the product provide For an accurate processing of Al/Cu and copper conductors leading manu-
forward. To ensure a safe and correct (oxide barrier) • sector stranded conductor (sm) the installer with essential informa- compression cable lugs it is generally facturers such as Klauke offer reduction
connection the use of special alu- that no moisture can enter the connec- compression joints with a cross section
minium/copper cable lugs and connec- When metals are connected to those tions. In an environment where mois- range from 10 mm2 up to 300 mm2.
rm – round stranded conductor
tors are essential. ( P i c t u re 1 ). with a higher electrical potential such ture is present the contact points ( s e e p i c t u re 7 ). These products serve
as copper in the presences of an elec- between the copper and aluminium mainly the reconstruction of power
Aluminium-Copper: trolyte (condensed water) will result in need to be protected by using accurate lines, i.e. non-tension connections of
A problematic connection an electrochemical reaction taking operating procedures. ( s e e p i c t u re 2 ). aluminium conductors acc. to DIN EN
Greenlee CSJ-100 open jaw meter

Source: Klauke
place. During this process the differ- Primarily this requires the use of alu- 60228 resp. aluminium wires acc. to DIN

Source: Klauke
Generally aluminium is a reactive mate- ences caused in electrochemical poten- minium/copper cable lugs and connec- EN 50182 with copper cables acc. to DIN
rial that oxidizes easily, but in practice it tial can have a significant impact. tors. Due to the design of these lugs Non-contact voltage detection in the narrowest spaces – 48201, part 1 and copper conductors
sm – sector stranded conductor
has proved to offer good corrosion areas where moisture could accumu- the Greenlee CSJ-100 digital open jaw meter makes it Picture 6: High quality aluminium cable acc. to DIN EN 60228. These compres-
resistance. This characteristic is due to a An electrical circuit is generated by late and where the oxidation process possible. Picture 4: lugs come with a special compound which sion joints consist of interconnected
chemical reaction that takes place the copper electrode (anode), the elec- could start have been avoided. For this Various shapes improves the contact properties and ensures aluminium (E-Al) and copper parts (acc.
when in contact with atmospheric oxy- trolyte (water) and the aluminium elec- reason aluminium/copper cable lugs It is designed for AC current measurements of up to of aluminium a perfect electrical connection. to EN 13600).
gen resulting in a very thin but also trode (cathode). The voltage generated and connectors are specified for the use 200 A AC and for AC and DC voltages up to 1000 V. It conductors
in this copper and aluminium circuit in off-shore wind power stations. meets the requirements of safety category IV up to 600 V or Normally the aluminium part of
“semi metallic” state results in a short category III up to 1000 V. the cross section has a much larger
circuit. Aluminium/copper compression diameter ( s e e p i c t u re 8 ) to compen-
cable lugs Additional product features are the data-hold-function sate for the poor conductivity of alu-
As a result of the current generated Picture 7: Aluminium and copper minium. As with the cable lugs here too
for recording measurements, the automatic power-off
the Aluminium surface breaks down Leading manufacturers of high quality conductors with different cross plastic plugs are used to prevent
for longer battery life, an audible continuity check and a
causing the metal to electrolytically compression cable lugs for connecting sections are being connected drying-out and leakage. Important:
diode test.

Source: Klauke
decompose. This destructive process is aluminium connectors with copper bus using reduction sleeves. The use of Al/Cu compression joints
visible as a kind of blooming oxidation bars ( s e e p i c t u re 3 ) consist of an elec- requires that the correct processing
Source: Klauke

and begins already with the existence trolytic aluminium (E-Al) compression guidelines for copper and aluminium
of tiny copper particles on the alu- and are joined to a copper palm (to EN are observed.
minium; this ongoing reaction itself 13600).
does not cause the copper to corrode. Consequently the aluminium section
In an electrical connection however the The available cross sections range needs to be crimped like an aluminium
Picture 1: Use of an incorrect crim- resistance is increased leading to from 16 mm2 up to 400 mm2. The field Picture 8: Normally the aluminium compression cable lug (see above).
ping die and/or an incorrect crimp increased temperatures which then in of application covers in principle all section (right) has a larger diameter Characteristically for Al/Cu compression
will result in an over compression the worst case lead to a fire. non-tension connections of aluminium than the copper section (left) to equalize joints are the different crimping marks
(right) or an under compression cables acc. to DIN 48201, part 1, and the poor conductivity of aluminium. which are 7 mm on the aluminium sec-

Source: Klauke
(left) and in the worst case in fire. Therefore when connecting copper aluminium ropes acc. to DIN 50182. www.klauke.com tion and 5 mm on the copper part for
and aluminium it is important to ensure Specifications and processing of alu- crimping dies up to 60 kN.

2 de Special 4 de Special
Electroinstallation IN BRIEF Electroinstallation
Copper and Aluminium conductors
are difficult to connect to each other.
It is therefore necessary to avoid the
ingress of moisture at all costs. For

Accurately connecting these applications special cable lugs


are needed and accurate operating
procedures should be adhered to.
minium / copper compression cable lugs
are the same as those for pure alu-
minium versions.
tions. Marking “16 KL25 150 rm/sm 185
re/se” stands for
recommended to use hexagon crimp-
ing dies acc. to DIN 48083 part 4. In
order to ensure an accurate and profes-
mend using the manufacturers crimp-
ing tools to crimp their cable lugs.
should be used, Klauke manufactures
aluminium dies in a silver colour
while dies for copper are yellow-gold

copper and aluminium Quality products manufactured by


• 16: Metric bolt size for connecting
bolt – size M16.
sional crimp avoiding over or under
compression is the use of appropriate
For instance the special crimping
dies for aluminium have a crimp width
coloured.

market leaders such as Klauke feature a • KL: Manufacturer crimping tools. Poor crimps can result in of 7 mm, i.e. 2 mm wider than the Connecting compound for alumi-
Copper due to its outstanding electrical properties are always consistent material thickness, exact (in this case Klauke) an increase in joint resistance and tem- crimping dies for copper cable lugs and nium connecting material
the first choice when selecting a conductor for an electrical diameters and correct fit are a prereq- • 25: Die code peratures that can lead to fires. To pre- connectors. This, however, only applies
uisite for ensuring high safety stan- • 150: Cross section of conductor vent such issues Klauke solely recom- to 60 kN crimping dies. The reason for All cable lugs and connectors for alu-
connection. A practicable alternative in many cases is aluminium
dards are always met. Like aluminium in mm2 this is that dies with a larger crimp minium conductors come with a special
particularly because of its low weight and easy application. In compression cable lugs conforming to • rm/sm: for round multi-stranded and width are able to connect a wider con- compound ( s e e p i c t u re 6 ). This aggra-
practice however the electrician can find it challenging to connect DIN 46239, aluminium/copper compres- sector stranded conductors ductor surface area with the cable lugs vates the non-conductive oxide layer

Source: Klauke
both these materials in a professional manner. sion cable lugs feature a barrier design • 185: Cross section of conductor and balance the poor conductivity of which is quickly formed on the surface.
allowing the use of oil soaked and in mm2 aluminium. To easily identify which die This compound improves the contact
paper insulated cables which prevents • re/se: for round single stranded solid properties and enables a perfect elec-
oil leakage. Picture 3: A professional connection and single sector solid conductors trical connection, and also prevents fur-
of an aluminium conductor with a ther oxygen penetrating the contact
Aluminium conductors copper busbar is done by means of The die code also needs special con- re – round solid conductor joints where further oxidation could

A
copper-aluminium connection at a glance an aluminium cable lug and a copper sideration. For an accurate and safe take place. To maintain the functional
is used for instance in an indus- Picture 2: The construction of Al/Cu palm. crimp the die reference should be the capability of the compound all leading
trial estate where local business cable lugs prevents any gaps which Aluminium conductors are available in same as that shown on the cable lug. Source: Klauke brand cable lugs are sealed with a plas-
use copper supply cables which are would allow the accumulation of four different versions which require in These abbreviations will be found The die code can be seen on the die Picture 5: The markings on the cable lug provide tic plug to prevent the compound from

Source: Klauke
then fed off an aluminium ring main. liquid to take place which would start some cases special processing. These next to other markings on all Al/Cu face as a mirror image so that after information relating to the crimps, the manu- drying-out and leakage.
But also in electrical substations it is the oxidation process. are ( s e e p i c t u re 4 ). compression cable lugs and identify compression the die code is visible on facturer, cross section and allocation of cable.
necessary to connect aluminium con- which conductors will suit the appropri- the cable lug for final control and se – sector solid conductor
Al/Cu Connectors
ductors to copper bus bars. The main • round solid conductor(re) ate cable lug. ( s e e p i c t u re 5 ). inspection.
problem here is that connecting alu- • sector solid conductor(se) For a correct connection of aluminium
minium and copper is not straight- very resistant oxide layer being formed. • round stranded conductor (rm) Markings on the product provide For an accurate processing of Al/Cu and copper conductors leading manu-
forward. To ensure a safe and correct (oxide barrier) • sector stranded conductor (sm) the installer with essential informa- compression cable lugs it is generally facturers such as Klauke offer reduction
connection the use of special alu- that no moisture can enter the connec- compression joints with a cross section
minium/copper cable lugs and connec- When metals are connected to those tions. In an environment where mois- range from 10 mm2 up to 300 mm2.
rm – round stranded conductor
tors are essential. ( P i c t u re 1 ). with a higher electrical potential such ture is present the contact points ( s e e p i c t u re 7 ). These products serve
as copper in the presences of an elec- between the copper and aluminium mainly the reconstruction of power
Aluminium-Copper: trolyte (condensed water) will result in need to be protected by using accurate lines, i.e. non-tension connections of
A problematic connection an electrochemical reaction taking operating procedures. ( s e e p i c t u re 2 ). aluminium conductors acc. to DIN EN
Greenlee CSJ-100 open jaw meter

Source: Klauke
place. During this process the differ- Primarily this requires the use of alu- 60228 resp. aluminium wires acc. to DIN

Source: Klauke
Generally aluminium is a reactive mate- ences caused in electrochemical poten- minium/copper cable lugs and connec- EN 50182 with copper cables acc. to DIN
rial that oxidizes easily, but in practice it tial can have a significant impact. tors. Due to the design of these lugs Non-contact voltage detection in the narrowest spaces – 48201, part 1 and copper conductors
sm – sector stranded conductor
has proved to offer good corrosion areas where moisture could accumu- the Greenlee CSJ-100 digital open jaw meter makes it Picture 6: High quality aluminium cable acc. to DIN EN 60228. These compres-
resistance. This characteristic is due to a An electrical circuit is generated by late and where the oxidation process possible. Picture 4: lugs come with a special compound which sion joints consist of interconnected
chemical reaction that takes place the copper electrode (anode), the elec- could start have been avoided. For this Various shapes improves the contact properties and ensures aluminium (E-Al) and copper parts (acc.
when in contact with atmospheric oxy- trolyte (water) and the aluminium elec- reason aluminium/copper cable lugs It is designed for AC current measurements of up to of aluminium a perfect electrical connection. to EN 13600).
gen resulting in a very thin but also trode (cathode). The voltage generated and connectors are specified for the use 200 A AC and for AC and DC voltages up to 1000 V. It conductors
in this copper and aluminium circuit in off-shore wind power stations. meets the requirements of safety category IV up to 600 V or Normally the aluminium part of
“semi metallic” state results in a short category III up to 1000 V. the cross section has a much larger
circuit. Aluminium/copper compression diameter ( s e e p i c t u re 8 ) to compen-
cable lugs Additional product features are the data-hold-function sate for the poor conductivity of alu-
As a result of the current generated Picture 7: Aluminium and copper minium. As with the cable lugs here too
for recording measurements, the automatic power-off
the Aluminium surface breaks down Leading manufacturers of high quality conductors with different cross plastic plugs are used to prevent
for longer battery life, an audible continuity check and a
causing the metal to electrolytically compression cable lugs for connecting sections are being connected drying-out and leakage. Important:
diode test.

Source: Klauke
decompose. This destructive process is aluminium connectors with copper bus using reduction sleeves. The use of Al/Cu compression joints
visible as a kind of blooming oxidation bars ( s e e p i c t u re 3 ) consist of an elec- requires that the correct processing
Source: Klauke

and begins already with the existence trolytic aluminium (E-Al) compression guidelines for copper and aluminium
of tiny copper particles on the alu- and are joined to a copper palm (to EN are observed.
minium; this ongoing reaction itself 13600).
does not cause the copper to corrode. Consequently the aluminium section
In an electrical connection however the The available cross sections range needs to be crimped like an aluminium
Picture 1: Use of an incorrect crim- resistance is increased leading to from 16 mm2 up to 400 mm2. The field Picture 8: Normally the aluminium compression cable lug (see above).
ping die and/or an incorrect crimp increased temperatures which then in of application covers in principle all section (right) has a larger diameter Characteristically for Al/Cu compression
will result in an over compression the worst case lead to a fire. non-tension connections of aluminium than the copper section (left) to equalize joints are the different crimping marks
(right) or an under compression cables acc. to DIN 48201, part 1, and the poor conductivity of aluminium. which are 7 mm on the aluminium sec-

Source: Klauke
(left) and in the worst case in fire. Therefore when connecting copper aluminium ropes acc. to DIN 50182. www.klauke.com tion and 5 mm on the copper part for
and aluminium it is important to ensure Specifications and processing of alu- crimping dies up to 60 kN.

2 de Special 4 de Special
Electroinstallation www.de-online.info

Picture 9: When used in the


ground cast-resin joints protect
the connections against moisture.
It is important to consider that the
All in one. One for all.

Source: Klauke
connection is not subject to Hüthig & Pflaum Verlag GmbH & Co.
bending to avoid the risk of frac- Engineers professional tool-bag Fachliteratur KG
ture. Der Elektro- und Gebäudetechniker Lazarettstraße 4, 80636 München

The procedure for the copper sec- Advice: When using crimp connec-
tion is absolutely identical as on copper tions in the ground it should be strictly
compression cable lugs. The crimping observed that the connecting joints
marks on the product give detailed should be protected against moisture. de Special 22/2008
information as to origin and applica- ( P i c t u re 9 ). For this application Klauke
tion of the Al/Cu compression joints. recommends use of cast-resin joints. MEHR INFOS The quality bag comes with genuine
The marking “KL14 50 rm/70 re/se” sig- Klauke tools.
nifies For the application of Al/Cu com- Contribution on this issue
pression joints and cable lugs the fol- http://www.de-online.info/archiv/
2008/01-02/index.php?Page=
• KL: Manufacturer (in this case lowing should also be considered:
elektroinstallation04.html
Klauke) These products should not be exposed • Which cable lug for which appli-
• 14: Die code to bending stresses which could frac- cation?, “de” 1-2/2008, S.33
• 50: Cross section of designed ture the contact point. Application on http://www.de-online.info/archiv/
conductor in mm2 overhead lines is therefore excluded. 2008/08/index.php?Page=
• rm/sm: for round stranded and elektroinstallation02.html
KL390IS (6-pieces) KL130PM1IS KL130PM2IS
sector stranded conductors • Cable lugs for special applications,
Preview: Crimp profiles
• 70: cross section of solid conductor “de” 8/2008, S.27
at a glance http://www.de-online.info/archiv/
in mm2
2008/17/index.php?Page=
• re/se: for round solid and sector solid With a further feature story in one of elektroinstallation02.html
conductors the next issues of “de” we close the • Best Practise for Installation of
series on cable lugs and connectors. Aluminium Connectors, „de“

BRDESONDER222008GB 10.000 02/09 I


The marks on the copper section This article will deal with the various 17/2008, S.26 KL044200IS KL050205IS KL020165IS

also indicate the correct procedure. The crimp profiles which correct selection
standard suggests crimping dies acc. to depends very much on materials and Book on this issue
DIN 48083 part 1, 3 and 4 for solid-, fine cable types used. Schmolke, Herbert: Selection and
design of cables and conductors
and fine stranded conductors; for
2007.2, revised and extended edition.
braided round wires the standard 120 pages, paperback, with CD Rom,
refers to specifications of the manufac- 18€,
turer. Generally Klauke recommends Lutz Remmel, Product Manager ISBN 978-3-8101-0263-8,
KL745HK KL710 KL403
using hexagon crimping dies acc. to DIN Electrical connecting systems, www.de-online.info/ shop/
48083 part 4 for processing the copper Gustav Klauke GmbH fachbuecher/schmolke_kabel.html
section of their compression joints. www.klauke.com

The ideal companion for electricians, fitters or installation engineers:


The Klauke Engineers professional tool-bag has space for the complete
tool range and provides safe storage of laptop, documents, mobile phone or
business cards. The clever compartmentation as well as removable single
components turn the tool-bag into a very flexible system meeting all
day-to-day requirements.

For more information please visit www.klauke.com


ELECTROINSTALLATION:

Accurately
connecting copper
and aluminium ORGAN DES
5 de Special ZVEH
Electroinstallation www.de-online.info

Picture 9: When used in the


ground cast-resin joints protect
the connections against moisture.
It is important to consider that the
All in one. One for all.

Source: Klauke
connection is not subject to Hüthig & Pflaum Verlag GmbH & Co.
bending to avoid the risk of frac- Engineers professional tool-bag Fachliteratur KG
ture. Der Elektro- und Gebäudetechniker Lazarettstraße 4, 80636 München

The procedure for the copper sec- Advice: When using crimp connec-
tion is absolutely identical as on copper tions in the ground it should be strictly
compression cable lugs. The crimping observed that the connecting joints
marks on the product give detailed should be protected against moisture. de Special 22/2008
information as to origin and applica- ( P i c t u re 9 ). For this application Klauke
tion of the Al/Cu compression joints. recommends use of cast-resin joints. MEHR INFOS The quality bag comes with genuine
The marking “KL14 50 rm/70 re/se” sig- Klauke tools.
nifies For the application of Al/Cu com- Contribution on this issue
pression joints and cable lugs the fol- http://www.de-online.info/archiv/
2008/01-02/index.php?Page=
• KL: Manufacturer (in this case lowing should also be considered:
elektroinstallation04.html
Klauke) These products should not be exposed • Which cable lug for which appli-
• 14: Die code to bending stresses which could frac- cation?, “de” 1-2/2008, S.33
• 50: Cross section of designed ture the contact point. Application on http://www.de-online.info/archiv/
conductor in mm2 overhead lines is therefore excluded. 2008/08/index.php?Page=
• rm/sm: for round stranded and elektroinstallation02.html
KL390IS (6-pieces) KL130PM1IS KL130PM2IS
sector stranded conductors • Cable lugs for special applications,
Preview: Crimp profiles
• 70: cross section of solid conductor “de” 8/2008, S.27
at a glance http://www.de-online.info/archiv/
in mm2
2008/17/index.php?Page=
• re/se: for round solid and sector solid With a further feature story in one of elektroinstallation02.html
conductors the next issues of “de” we close the • Best Practise for Installation of
series on cable lugs and connectors. Aluminium Connectors, „de“

BRDESONDER222008GB 10.000 02/09 I


The marks on the copper section This article will deal with the various 17/2008, S.26 KL044200IS KL050205IS KL020165IS

also indicate the correct procedure. The crimp profiles which correct selection
standard suggests crimping dies acc. to depends very much on materials and Book on this issue
DIN 48083 part 1, 3 and 4 for solid-, fine cable types used. Schmolke, Herbert: Selection and
design of cables and conductors
and fine stranded conductors; for
2007.2, revised and extended edition.
braided round wires the standard 120 pages, paperback, with CD Rom,
refers to specifications of the manufac- 18€,
turer. Generally Klauke recommends Lutz Remmel, Product Manager ISBN 978-3-8101-0263-8,
KL745HK KL710 KL403
using hexagon crimping dies acc. to DIN Electrical connecting systems, www.de-online.info/ shop/
48083 part 4 for processing the copper Gustav Klauke GmbH fachbuecher/schmolke_kabel.html
section of their compression joints. www.klauke.com

The ideal companion for electricians, fitters or installation engineers:


The Klauke Engineers professional tool-bag has space for the complete
tool range and provides safe storage of laptop, documents, mobile phone or
business cards. The clever compartmentation as well as removable single
components turn the tool-bag into a very flexible system meeting all
day-to-day requirements.

For more information please visit www.klauke.com


ELECTROINSTALLATION:

Accurately
connecting copper
and aluminium ORGAN DES
5 de Special ZVEH