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de Special 17/2008

ELECTROINSTALLATION :

Best Practise for

Installation of
Aluminium Connectors ORGAN DES
ZVEH
Electroinstallation
Best Practise for
Installation of Aluminium Connectors
Aluminium compression cable lugs and
connectors according to DIN.
Material properties of aluminium cable are very different from those
of copper. For safe electrical connections, solely compression cable
lugs or connectors manufactured from aluminium are to be used. In
addition due to certain specific material properties, the installation
procedure has to be carefully observed.
T
he advantages of aluminium are
increasingly coming to the fore
in power distribution applica-
tions, due to the lower material weight
and the relatively simple handling.
Power utilities tend to install more and
more aluminium cables, for instance
ring mains for urban power supplies.
In principle it is recommended to use
solely high quality aluminium com-
pression cable lugs with tube di-
mensions acc. to DIN 46329 and alumi-
nium connectors with tube dimensions
acc. to DIN 46267 part 2. Products of re-
nowned manufacturers such as Klauke
are made from premium electrolytic
aluminium alloy. These products fea-
ture a constant material thickness,
exact diameter and a correct fit which
ensures simple installation and ab-
solute safety. Standard cross sections
range from 10 mm2 up to 500 mm2.
Special sized cross sections are available
up to 1000 mm2, for instance for sub-
sea cables with high transmission capa-
cities.
Aluminium compression cable lugs
feature a barrier design. (acc. to DIN
46239) which allows installation on oil
impregnated, paper insulated cables
Installation
of com-
pression cable
lugs and connectors
for aluminium conductors is
very different from installation of
copper conductors. Failure of vital
installation procedures can lead to a severe
lack of safety.
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AT A GLANCE
In the worst case an incorrectly in-
stalled aluminium cable lug can result
in a serious fire. In this article we give
recommendations for a professional
installation.
and consequently provides a firm
Source: Klauke
water/oil block. Picture 1:
The barrier design
Aluminium conductors at with oil stop prevents leakage
a glance : of oil of the paper insulated
conductor.
Aluminium conductors are available in
four different types (picture 2) which in
some cases require special installation re = solid round conductors
procedures. These are
• re = solid round conductors
• se = solid sector conductors se = solid sector conductors
• rm = round stranded conductors
• sm = sector stranded conductors
These abbreviations can be found on rm = round stranded conductors
aluminium compression cable lugs to
make sure the correct cable lug is used
with the appropriate aluminium
Source: Klauke
conductor. (Picture 3). sm = sector stranded conductors
All markings on aluminium com-
pression cable lugs are in conformity Picture 2: Different types of
with those on copper cable lugs and aluminium conductors
indicate the manufacturer, dimensions
and type of product. For example
marking “KL 18 10-70 /rm/sm 95 re/se”
denotes:
• KL: manufacturer (in this case
Klauke)
• 18: die code
Source: Klauke
Picture 3: Markings on the
cable lugs indicate manu-
facturer, bolt size, cross
section and cable assignment.
Source: Klauke

• 10: metric bolt size (bolt M 10)
• 70: nominal cross section of
conductor in mm2
• rm/sm: for round stranded and
sector stranded conductors
• 95: nominal cross section of
conductor in mm2
• re/se: for solid round conductors and
solid sector conductors
Important: The nominal cross sections
of se and re conductors are always
one cross section size above the cross
sections of sm and rm conductors. This
is due to solid conductors having a
smaller diameter than their stranded
equivalent.
Special attention should be given to
the die code: For a professional in-
stallation the crimping dies of the
appropriate tool must be matched with
the code of the cable lugs. (Pictures 3
and 4). Die codes on crimping dies are
mirror-inverted – after the crimping
operation the die code is clearly visible
for quality control and documentation.
For a professional installation hexa-
gonal crimping dies (acc. to DIN 48083
part 4) are recommended. The visible
signs of a correctly crimped lug are the
same for copper connectors as they are
for Aluminium: In order to achieve
a professional installation – with no
over or under crimping – the use of
the appropriate tool is essential. An
incorrect installation can result in in-
creased joint resistance and even in
fire. (Picture 5). To avoid such con-
sequences Klauke recommends to use
the same manufacturers tool as the lug
or connector. This ensures a matched
system. For instance the specific dies for
aluminium have a crimping ‘bite’ width
of 7 mm, which is 2 mm wider than for
copper lugs and connectors (Picture 6).
The reason for this is that wider com-
Picture 5: Over compression (left) is the result of a crimping die which is too small, whilst under compression
(middle) is caused by the use of a crimping die which is too large. The picture on the right shows a correct crimp
using an appropriate crimping die.
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MORE INFORMATION
Book on this issue
Schmolke, Herbert: Selection and design
of cables and conductors 2007.2, revised
and extended edition. 120 pages, paper-
back, with CD Rom, 18€,
ISBN 978-3-8101-0263-8,
www.de-online.info/ shop/
fachbuecher/schmolke_kabel.html
Picture 4: Imprint of die code “18” on the cable lug (left) indicates the
crimping die used. Completed crimp (right) with marking “18” on the
cable lug refers to the correct crimping die.
pression areas result in better conduc-
tivity and therefore compensate for the
poorer electrical properties of Alu-
minium. In order to determine the
different dies required Klauke manu-
facture the Aluminium dies in silver and
the Copper dies in a yellow gold colour.
Compound for Aluminium
Connectors
Cable lugs and connectors for alu-
minium are supplied with a special
compound within the barrel (picture
7a). During crimping, this compound
destroys the non-conductive oxide
layer on the aluminium in the crimping
area, increases the contact properties
and ensures the correct electrical
Electroinstallation
Contribution on this issue
http://www.de-online.info/archiv/
2008/01-02/index.php?Page=
elektroinstallation04.html
• Which cable lug for which appli-
cation?, “de” 1-2/2008, S.33
http://www.de-online.info/archiv/
2008/08/index.php?Page=
elektroinstallation02.html
• Cable lugs for special applications,
“de” 8/2008, S.27
Source: Klauke
connection. In addition the compound
prevents admission of oxygen and
consequently avoids any further oxi-
dation (Picture 7b). To maintain the
functional properties, brand-name
cable lugs are sealed with a plastic plug
to prevent the compound from drying-
out and leaking. (Picture 8).
Compounds for aluminium con-
nectors contain additives such as
corundum, a material similar to sand,
which exhibits high resistance and
hardness, temperature stabilising pro-
perties and extreme wear and cor-
rosion resistance. A grinding effect is
generated during crimping which
cracks the hard oxide layer on the
cable. In addition the compound aids
Source: Klauke
3
 Electroinstallation

position, and consequently number of

crimps required. This is dependant on if
you are using narrow or wide crimping
dies (picture 9). ‘Narrow’ crimps
(approx 7 mm) are performed by tools
of at least. Also the correct crimping
Source: Klauke

direction has to be observed – always

Picture 6: The contact surface (bite width) of crimping dies for aluminium cable
lugs (left) are 2 mm wider than their copper equivalent (right).
the dynamic friction between the
conductor and sleeve, which prevents
jamming of materials and helps to
provide a clean contact surface. When
used on stranded conductors, the
compound is distributed between the
individual wires during the crimping
process and seals them against oxygen
and moisture ingress.
It is also important to know that
aluminium crimp connections installed
using compound perform much better
when subjected to high current loads
than those without compound. To
guarantee a safe connection, at high or
low loads, Klauke recommends com-
pression cable lugs and connectors with
compound.
Installation of aluminium
compression cable lugs and
connectors
In order to accommodate the special
characteristics of Aluminium material,
crimp in the direction of the conductor
(picture 10).
Outlook: Al/Cu Compression
cable lugs
the following five installation steps are
essential: A further important technical issue is
the correct method of connecting
• Remove insulaltion of aluminium aluminium and copper conductors. In
conductor one of our next issues we will report on
• Clean the blank conductor ends with aluminium/ copper cable lugs and
a wire brush to remove an oxid film connectors.
and to provide a clean surface
• Insert the conductor into the cable Lutz Remmel, Anwendungstechnik &
lug or connector to the recom- Application Engineering,
mended length. Some compound Gustav Klauke GmbH
will emerge from the mouth of www.klauke.com
the cable lug or connector which is
now hermetically sealed to prevent
further oxidation of the conductor.
• Start the hexagonal crimping ope-
ration with a suitable crimping tool.
Important: Sector shaped conductors
need to be pre-rounded with appro-
priate crimping dies.
• Remove any excess compound
emerging from the lug or connector.
Please note: All DIN compression cable
lugs show markings on the outside of
the barrel for the correct crimp

7a
Picture 9: Markings on the
cable lugs indicate number
and position of crimps as per
manufacturers recommendation.

7b
BRSONDER172008GB 10.000 10/08 I

Picture 7a: Compounds with

additives like corundum
all pictures – Source: Klauke

generate a “grinding effect”.

Picture 7b: The compound seals
the joint and prevents oxidation.
Picture 8: Plastic plugs prevent
compound from drying-out and
leaking during storage.
Picture 10: Start the first crimp
at the lug end and progress
towards the conductor to ensure
that compacted material ex-
pands in this direction.

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