Battery Crimping Tools For Versatile & Reliable Electrical Connections

By Chris Dodds on 19th May, 2015

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Battery Crimping Tools For Versatile & Reliable Electrical Connections

In this first of a new series of posts from electrical contractors, T&D and SEC Ltd discuss the working challenges and tooling solutions to crimping cables.

T&D are inviting more contributions from qualified and competent electrical contractors and thank SEC for helping write our inaugral post.

Should you yourself wish to highlight an electrical installation topic and promote your company, services and "know-how" just drop us a line.    

Electrical Contractors

Modern technological advances have improved the reliability of crimped cable connections with battery tools replacing hydraulic and ratchet type tools and revolutionising the termination of cables at both LV and HV.

Today, we focus on Klauke Crimping Tools and especially the battery powered types as we benefit from the practical experience of the user, in this case SEC Ltd.

SEC are industrial, commercial and domestic electricians specialising in UPS & Generator Installation and Electrical Inspection & Testing.

SEC are an NICEIC Approved Contractor. NICEIC has been assessing the technical competence of electricians for over 50 years.  

Who Are NICEIC?

NICEIC aims to protect everyone who uses electricity from unsafe electrical installations anywhere. To achieve this, NICEIC maintain a register of qualified, competent electricians.

NICEIC Approved Contractor

Let's jump straight in and hand over to John Woolley, MD of Specialist Electrical Contractors.

 

"At Specialist Electrical Contractors Limited, we use a wide range of cable sizes and types and terminating them in a quick and efficient manner is something we always strive to achieve and with advances in technology, especially battery hydraulic crimpers, have helped us to become more efficient. 

More work in less hours improves our manpower productivity and helps complete jobs early rather than late. Over the years we have used various crimping tools, from hand operated ratchet crimpers and star luggers to foot pump operated hydraulic crimpers!

We still use ratchet crimpers for the small stuff and the star crimpers are a handy back up if ever the battery ones fail but can be cumbersome to use as the tool handles are quite long and you need some room to be able to operate them fully.

The foot operated hydraulic crimpers were so heavy to use and always leaked fluid which prompted us to start looking at other options.

We have used battery operated hydraulic crimpers before but they tend to be fairly heavy and can be awkward when having to hold the cable in one hand and the crimper in the other.

We decided recently after a bit of market research to purchase the Klauke K505LSETHL Battery OperatedKlauke EK50-5-L Battery Crimping Tools Hydraulic Cable Crimper, and so far all I can say is wow!

We are very impressed.

Klauke K505LSETHL came with a full die set covering 6-240sqmm and uses Makita 18v Lithium batteries which ties in well as our drills are Makita and all share the same batteries and chargers.

The Klauke battery crimper weighs in at just 2.4kg and its weight is well balanced - portability is important on jobsites and the tool is self-contained in a handy carry case. With it being relatively small compared to others in the market it makes getting into small spaces a piece of cake!

We specialise in Generator and UPS installation at SEC and a lot of the time there isn't a great deal of space inside a UPS or Generator ATS panel to be able to lug off cables, the Klauke battery tool makes crimping so much easier and its size and weight makes it perfect for smaller spaces and ultimately SEC more efficient in our work."

Watch SEC Ltd demonstrate the simplicity of onsite cable crimping using Klauke Tools :

John is right. The ability to complete and crimp low voltage cable terminations in contained workspace allows the electrical contractor to achieve highest class workmanship - conventional C-shaped head crimping tools struggle to make-off cables in enclosed panels and switchgear. Where crowded cables congregate into electrical panels and actual working clearances are severely reduced then the choice of installation tooling can be a major factor in enabling a safe and reliable cable termination.   

Pictured : LV Power Cables Terminated Into Automatic Transfer Switches (ATS) For Generator Power Supply. BS5467 XLPE 240sqmm stranded copper power cables terminated alongside parallel 50sqmm cables and 6491X type earthing wiring cables to BS6004. Images : SEC Ltd.   

Battery Crimping Tools

Battery Crimping Tools - Klauke

 

Klauke EK 50/5-L Battery Powered Crimping Tool - Features & Benefits 

  • For interchangeable dies, series 5, narrow crimping
  • Closed crimping head, flip top style, rotatable
  • Electronic control and monitoring of crimping operation
  • Integrated pressure measurement with visual and audible signals
  • Evaluation function using optical interface and USB adapter
  • One-button operating concept for controlling all tooling functions
  • Ergonomic 2-component plastic housing with soft linings
  • Lightweight for effortless operations
  • LED for workplace illumination
  • High-performance 18V Li-ion battery with high capacity
  • High-performance motors for fast crimping cycles and efficient operations
  • Energy saving function by stopping motor after successful crimping process
  • Quick motor stop for high user safety
  • Automatic retraction when crimping is complete
  • Manual retract in case of need

Pictured : Klauke EK50-5-L Battery Crimping Tool

Klauke EK50-5-L Battery Crimping Tool


The Klauke EK 50/5L battery crimper also features a multi-function LED for maintenance control, charge level indicator of the battery and for data transmission via USB adapter.

Video : Klauke Cable Crimping & Cutting Tools Overview 

 

Cable Crimping Concepts

Cable crimping is a system of compressing a cable terminal, lug or splice to an electrical conductor by pressure forming or reshaping a metal barrel, together with the conductor, by the use of crimping tools.

The forming of an effective cable crimp depends upon 3 key factors : the correct combination of conductor, crimp barrel and tool. Manufacturers recommend a "matched" crimping system where tool, connector and die sets are not interchanged with other manufacturers, although in the field this is somewhat impratical more achievable and important factors can be adhered to when crimping cables. BS7609 provides British Standard guidance on cable crimping.

When applied with a properly matched tool a connection would be established which has both excellent electrical and mechanical characteristics. 

The electrical resistance of a properly designed and controlled crimp joint should be equal to, or less than, the resistance of an equal section of wire. Specifications state the requirements in terms of millivot drop at a designated current.

The mechanical strength of a crimped joint and hence its pull-out force (tensile strength), varies with the deformation applied. Therefore, by properly shaping the deformation of a high pull-out force can be achieved, i.e. the crimp die of the tool determines the crimp configuration and deformation.

 

Featured Product - EATON ATS Automatic Transfer Switches

Eaton's Automatic Transfer Switches guarantee reliable, seamless power when electricity outages impact upon power distribution networks. ATS's automatically transfer electrical power supply to the generator when utility power fails, providing the highest protection for continuous power. Eaton's unique active load control inside their GREEN ATSs allows users and owners to save money up front by downsizing the generator to purchase, providing ongoing savings in operating costs, by consuming less fuel each month.

 
Coming Soon. Read our second in this series of blogs from NICEIC registered electrical contractors. Here Mayhew Electrical will discuss the importance of installing the correct cable management system in accordance with BS7671 standards for Fire & Smoke Alarm Systems :

Mayhew Electrical - NICEIC Registered Electricians & Electrical Contractors - Fire & Smoke Alarm System Installers

Mayhew Electrical : Project Gallery (April 2015) Fire & Smoke Alarm Cabling and System - BS7671 Electrical Installations (IEE Wiring Regulations, 17th Edition)




Category:  Cable Crimping & Cutting Tools

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