Cable lugs for crimping: types, nuances of operation

Tinned copper is copper coated with a thin layer of tin or a tin-based alloy. In radio engineering, this is done to connect copper parts to each other in order to give the joint strength, reduce ohmic resistance, and counteract copper oxidation processes.

The production of tinned copper wire in industrial conditions is carried out using the galvanic method - the wire is immersed in a bath of molten metal, as a result of which its surface is evenly covered with a layer with a thickness of 1 to 20 microns - depending on the current strength involved in the electrochemical process. In order to achieve perfect uniformity of coating thickness, the wire is then passed through a drawing mechanism equipped with diamond discs.

The wire tinning process can be seen in the video below.

Where are cable lugs used for crimping?

We can talk endlessly about the areas of application of crimp wire lugs. In order not to overload the reader with unnecessary information, we will consider only the main ones:

• in production. Not a single connection of power lines to each other or to electrical equipment is complete without crimping the cable lugs. This ensures tight contact and, as a result, reliable operation of electrical appliances and equipment. The shape and size of such elements are selected according to the cross-section of the cores and the material of manufacture;

  
  The main advantage of such connections is reliability.

• household sphere. A home craftsman rarely thinks about the benefits of tips, but in vain. If we disassemble any household appliance, we will see that not a single connection is complete without them. In everyday life, elements that differ from industrial ones are used. But they perform the same function: tight contact, no heating and no need for periodic tightening of the terminals.

How to distinguish copper from other metals

For most of us, knowledge about copper and its properties is limited to a school chemistry course, which is quite enough at the everyday level. However, sometimes there is a need to reliably determine whether a material is a pure element, an alloy, or even a composite material. The opinion that this information is needed only by those who are engaged in the acceptance or delivery of scrap metal is erroneous: for example, on amateur radio forums, topics are often raised about how to distinguish copper in wires from copper-plated aluminum.

Marking and decoding

The industry produces a large number of all kinds of tips, which differ in design and materials.

Color coding option

There is a special marking system that allows you to distinguish the material and use it for its intended purpose. Here is a breakdown of some of the symbols:

• A – the sleeve is made of aluminum;
• L – brass is used;
• M – the base of the product is copper;
• T – the element is made of tubular metal;
• U – the connector is made in the shape of an angle.

There is also a designation in the form of the letter O, which indicates the presence of an inspection window through which you can make sure that the cables are correctly located in the sleeve inside.

If the marking is TML (O), then it means tinned tubular copper with an inspection window. NSHVI - means a pin sleeve tip, and NKI - a ring one. In this case, the numbers indicate the cross-sectional area or diameters of the rod. To make it easier to find suitable connectors, for example, NShVI or KVT, you can use a special catalog or tables.

After the letter designations in the markings there are usually numbers that contain information about:

1. nominal section;
2. diameter of the contact rod;
3. internal diameter of the shank.

For example, the product is marked TML (O). This means that this wire termination is made of copper tubing and is tinned. Its distinctive feature is the presence of a small hole - an inspection window, with which you can verify whether the wire is inserted correctly for crimping.

Such contacts are used mainly in production, so not all electricians are aware of their existence.

Characteristics

The main distinguishing feature between them is the ability to bend. The diameter of tinned copper and aluminum can differ significantly. The most widely used wire is the one whose diameter is in the range of 0.02-9.42 mm.

To make it, use ordinary copper wire on a reel, subjecting it to galvanic tinning. The material is passed through a tin bath containing molten tin. To prevent it from entering into oxidation with oxygen in the air, the surface of the bath is covered with substances that cannot allow air to pass through. In particular, such a substance may be charcoal.

What does the tip marking mean: full explanation

Each type and type of product has its own alphanumeric marking, without knowing which it is impossible for a home craftsman to explain in the store what he needs. Let's look at popular markings:

• TML is a tin-plated tip, to work with which you need a special tool - a crimper. Looks like NSP. The only difference is that NShP is copper;
• TA – the same tip, but made of aluminum;
• SIP is a self-supporting tip that has its own insulation along the tube and an annular mounting plate;
• NSHVI - common in household use, sleeve pin;
• NKB - used in industry as geophysical cable;
• RFI-M is already a flag tip;
• IEK – copper fork;
• TMD – double blind connectors;
• NKI - isolated ring.

Aluminum products are regulated by GOST-9581-80, copper - GOST-7368-80.

Products for crimping are made of copper, aluminum or bimetal

What is tinned copper?

Copper becomes tinned after it is treated with tin, another metal or its alloy. In most cases, copper is coated with tin, since this element is inexpensive and at the same time gives the copper product new properties: strength, resistance to damage, and others. As a result, the material becomes more durable, its service life increases, and it is also resistant to external negative phenomena such as corrosion. The tin coating protects the material from chemical aggression and mechanical damage as a result of impacts or falls. Tinned copper is widely used in the construction and repair industry, in the production of drainage systems and in the production of electrical equipment. Our company is engaged in receiving tinned copper. We can also sell copper at a high price.

Types of tips by design

Depending on the design of the terminal and the connected electrical appliance, the shape of the tip is selected. It comes in several types.

The lugs can be used to connect one or two wires; for the second case, special parts are produced. Fixation is carried out by crimping or a bolt built into the shank. The first option is most applicable in everyday life and in production; it is intended for flexible wires made of multiple cores. The second is suitable for rigid cables.

How to choose the right tip for crimping

The correct choice of this electrical installation element depends on the material of manufacture, flexibility, cable cross-section, as well as the method of connection to the device or equipment:

1. Cable cross-section is an important aspect. If it is larger, the cable simply will not fit into the sleeve, and if it is smaller, the crimp will not be tight, and there is no point in such a tip.

   
   NShVI are usually sold in such sets, but can also be purchased individually

2. Flexibility of the wire – this can also lead to a loose connection. For example, we use a product with a bolted connection and a flexible electrical cable. When screwed in, the bolts push the wires apart, pressing only a few “hairs” in the middle. There is no talk of any contact anymore.
3. The method of connecting to the equipment may also differ. If switching is not possible with a direct connection, it is necessary to use.

Delivery of scrap tinned copper

We accept scrap tinned copper. Our non-ferrous metal collection centers are located throughout Moscow and the region. Because tinned copper is plated, when calculating the weight and price of scrap, a specific percentage is subtracted from the total weight, which is the weight of the tin or other material used for the coating. The cost of scrap is also influenced by the following factors:

• The absence of impurities of other metals that are not provided for according to the rules for the manufacture of tinned copper.
• The absence of non-toxic additives in the batch, which include: paper, plastic, garbage, and so on.
• The radiation background of the scrap being handed over is not exceeded.
• Lack of small-sized wire with or without firing.

In addition to the above, the cost of scrap directly depends on the volume of the batch. The greater the mass of scrap being delivered, the greater the cost per kilogram.

It is worth noting that there are fewer requirements for mix copper scrap, which is a mixture of copper waste. You can also hand over the copper mix to us.

Main types of lugs for crimping

Depending on the material from which the tips are made, there are several types of these elements:

• copper – used for cables made of copper conductors;
• tinned copper – tinning treatment provides protection against corrosion;
• aluminum – suitable for aluminum wires;
• aluminum-copper - allow you to connect aluminum and copper wires.

Elements can have different cable connector diameters and bolt mounting holes, different blade sizes and shapes. Some of them are equipped with an inspection window that allows you to adjust the position of the cores inside the part.

Types of tips by material

Copper cable lugs: general information

Copper cable lugs for crimp testing are made from copper pipes of a certain diameter. The pipes are cut and flattened on one side. A hole of a certain diameter for a bolt is made in the flattened part. Produced at special enterprises.

There are two types of copper cable contacts:

1. uncoated cable lugs;
2. with tinned coating.

Tinned contacts are considered more practical to use. Tinned coating protects the part from corrosion and extends its service life. In addition, tinned contacts are resistant to solutions of nitric, sulfuric and hydrochloric acid.

They are not afraid of exposure to air, moisture and other aggressive environmental factors. Due to the coating, the electrical conductivity of the terminals is reduced. However, it consistently maintains excellent performance.

But uncoated copper contacts will oxidize very quickly. Because of this, the conductivity indicator decreases, the resistance increases, which leads to heating of the connection.

The lugs are used for terminating cables with copper cores. For their installation, special press pliers are usually used, which are used to crimp the end onto the cable.

Copper cable lugs for crimping are used for:

• establishing communication between the power grid and the device;
• establishing contact between devices or a group of devices;
• splicing several electrical wires to increase the length.

Homemade copper

Today there are many cable copper crimp terminations, which, in particular, are very easy to decipher. But there are cases where it is impossible to select a cable lug of the required volume. Then it is possible to use a non-standard option - to create one yourself.

The creation process is simple. To do this, you need to take a copper tube with a certain size. Next, flatten the end and make a hole with the desired diameter.

Homemade copper

NShVI pin lug

NSHVI - insulated pin sleeve end. The sizes of NShVI tips are from 0.25 to 150 mm. Made from tinned electrolytic copper. Designed for household use, suitable for any multi-core wires.

Advantages of tinned copper wire

Tinning the surface of copper with tin protects it from the destructive effects of atmospheric oxygen, increases tensile strength and resistance to fracture during repeated bending, and simplifies the soldering process. Poluda - the so-called tin film - also protects copper from the harmful effects of sulfur, which is part of the rubber and plastic from which the wire insulation is made. As a result of all this, the service life of the wire increases.

To summarize, cables with tinned copper conductors:

• stronger
• more durable
• more flexible
• easier to install

The main consumer of tinned copper wires is the electronics and electrical industry.

Sleeves for wires for crimping

Sometimes there is no need to use a ferrule, but crimping the wires with sleeves is required. They can be of two types - GML (tinned copper sleeve) or GAO (copper-plated aluminum sleeve). The choice depends on the cable material.

Good to know! When connecting aluminum wires, it is advisable to use quartz vaseline paste. It prevents the oxidation process from occurring.

Twisted pair cables are crimped in a similar way. The only difference is in the matrices

How to distinguish between copper and its alloys?

Copper alloys are widely used in industry. Over many years of research, it has been possible to obtain many materials with unique properties: high ductility, electrical conductivity, chemical resistance, strength (all depends on alloying additives). The most common are bronze (with the addition of tin, aluminum, silicon, manganese, lead and beryllium), brass (with the addition of 10-45% zinc), as well as copper-nickel alloys (nickel silver, cupronickel, copel, manganin).

Only bronze and brass are difficult to identify, since copper-nickel alloys differ significantly in color due to their low copper content.

Copper or brass?

Brass can contain from 10 to 45% zinc, a silver-gray metal. Naturally, the more zinc, the paler the alloy. However, high-copper brasses, in which the amount of additives does not exceed 10%, differ little in color from the copper sample. In this case, you can only trust your feelings: brass is much harder and more difficult to bend (for greater reliability, a comparison with a reference sample is advisable). You can try to remove the shavings: copper shavings will have a curl shape, brass shavings will be straight, needle-shaped. When the samples are placed in a solution of hydrochloric acid, no reaction with copper is observed, and a white coating of zinc chloride forms on the surface of the brass.

Copper or bronze?

Like brass, bronze is much stronger, which is explained by the presence of harder metals in the alloy. The most reliable test will be a “tooth test” - there is unlikely to be a trace of pressure left on the surface of the bronze.

You can also experiment with a hot saline solution (200 g of table salt per 1 liter of water). After 10-15 minutes, a copper sample will acquire a more intense shade than a bronze one.

Why crimping?

Soldering a stranded wire is not the easiest operation, because you need to expose all the wires, make sure that they are clean in terms of contact, and only then start soldering. Any core in a stranded wire has insulation, and this often creates difficulties in establishing reliable contact.

Just crimping the cable lugs solves all these problems, because with the help of mechanical force (compression) not only the insulation of individual cores is destroyed, but also a strong connection of the entire cable is created for better contact.

This is where the moment arises of how to choose the correct sleeves for crimping wires, because they are made from different materials and have very precisely specified current characteristics.

The problem is that the size of these cartridges is small, and the markings are unclear to those who are not specialists. But before that, let's define the difference between a sleeve and a cable crimp lug.

Another point that is not even in the markings is the moment of tightening the sleeve or tip during crimping. And they are completely different for different types of tips, such as:

• ring (NKI).
• fork (NVI).
• pin round (NSHKI).
• flat (plug) connectors (RPI-P, RPI-M, RSHI-P, RSHI-M, etc.).
• piercing type couplers (OV).

Here it is necessary to return to the tool that is used to crimp the wires, because on each tool the dimensions are indicated for the standard shape of the jaws, and the force itself is accurately measured by diameters. So, unless you made a mistake with the diameter, you cannot apply excessive force.

And, despite the fact that the lugs for wires for crimping are different, with the same diameter both the force and the standard of the tool will be the same. It's a pity that this parameter is not reflected on the labeling. Apparently because such work is usually done by professionals, not home electricians.

But it is precisely the standards that allow home electricians to stock up on universal crimping pliers and crimp cable lugs for their own purposes without any problems. This procedure is quite simple to master, and technologically it is the same for crimping an RG-45 connector and a tip for a three-phase machine.

When crimping a multi-core cable, you cannot do without special lubricants. Therefore, use sleeves and tips that already have this lubricant inside. In any case, this is a one-time operation. It is not possible to remove a part to move it to another location.

As a result, having mastered the installation of sleeves and tips, you will be able to quickly restore the desired connection, carry out repairs without problems, as well as a connection that, in fact, will not need repair for many years.

Preparation for crimping

To crimp using a cable lug, you need to prepare the wire. See the table below for how to do this.

Procedure for crimping cable lugs and sleeves

For crimping thick-walled tips and sleeves, it is best to use a hydraulic press. The press set initially includes universal dies for any tips and wires.

Under no circumstances use a tool not intended for crimping (hammer, chisel, etc.). A contact pressed in this way will not last long, especially if it constantly experiences heavy loads.

The next question that arises for an ignorant user is: how many times should I press the tip with a press? Once, twice or three times?

This depends on 2 parameters - the length of the tip and the width of the matrix.

In the operating instructions for the press that comes with the tool, there is a sign indicating the required number of crimps. Please note that this table is intended for tips and sleeves made in accordance with GOST.

Insert the tip into the press so that the matrix cross-section markings (35-50-70, etc.) are imprinted on the front side of the tip, and not on the side or bottom.

1. do the first crimp test closer to the blade (where the bolt is inserted);
2. Perform the following crimps in order, moving from the blade to the tail of the tip.

The same rules apply for connecting sleeves.

This must be done in this sequence, because with each press the tip tends to lengthen (sometimes up to ten percent!).

And if you start pressing from the end (not from the blade), during the last crimp, there is a high probability that you will have a void at the end of the sleeve. And you will not achieve the contact that was necessary. First of all, this applies to all aluminum products. For copper this is not yet so critical.

Ferrule crimping

To find out which tool is best to use for crimping various types of tips, watch this video:

As you can see, you don’t need any special intelligence or experience to use the tips; everything is done easily and quickly. The only thing you will need are special devices - a stripper and press pliers, but they are affordable and can be purchased. When connecting multi-core conductors, be sure to use lugs and make the power supply as reliable and safe as possible.

How to crimp a wire: instructions for single and double NShVI

The wire with the tip must be installed in press jaws in a matrix of a suitable size. During the crimping process, you need to ensure that the wire does not move inside the sleeve. The first crimp is done with an indentation of 1–2 mm from the edge, if necessary, the second at the same distance from the first.

The handle of the press pliers is compressed until it is in full contact with the surface of the part and the matrix is ​​connected, then the sleeve is moved and a second crimping is done. If the shank is long, work continues until the colored skirt.

The crimping scheme for a double tip is practically the same. You only need to insert two wires into one hole in the shank at the same time.

Stages of wire crimping

Visual instructions for crimping a wire with an NShVI lug are presented in the video:

Crimping power cable lugs

When crimping power cables, tinned copper lugs are used, which are well protected from corrosion. If, when cutting the cable, its cores “fluff” significantly and become larger in diameter than the rest, then perform the work on a sharpener. When unrolling the cable, make sure that the circle removes excess knots along the cores and does not bend them.

Soldering is absolutely not suitable for crimping a power cable, since single tin contacts cannot be used on such wires.

Features of soldering iron tinning

The essence of tinning is to coat a copper part with a thin layer of tin, which protects the product from corrosive processes. Soldering iron servicing has some distinctive features.

It is important to prepare your work surface first. Take a new soldering iron and sharpen the tip of the device. To do this, the tip is pulled out, armed with a soldering iron or an electric machine, at an angle of up to 400, then sharpened. If the soldering iron is being prepared to work with small radio components, it must be given a conical shape.

Professionals recommend ensuring that the width of the sharp wedge is not less than a millimeter. If the shape of the tip proposed by the manufacturer suits the consumer, you can skip this stage. Since at the factory the soldering iron rod is coated with patina - greenish copper oxide, it is important to remove the coating with an abrasive material (sandpaper) before tinning. Next, the tip is returned to the device, and the soldering iron is connected to the electrical network. You need to wait until the surface of the tip warms up evenly, and then proceed to tinning.

Why can't you twist the wires?

The wires inside the bushing are crimped under very high pressure, so that they can even change their original circular shape if they lie parallel to each other. From a circle they turn into a hexagon, and this increases the area of ​​​​their contact surface with each other.

And when you twist them, during crimping, in those places where the veins intersect, they can be pressed against each other.

Required Tools

Crimping is carried out with a special tool that allows you to create the necessary force. The following tools are popular:

• Press pliers for crimping PK2 and PK2M lugs are used for terminating cores with a cross-section of up to 10 sq. mm;
• PK1 and PK1M brand tools are a more powerful version of hand pliers;
• hydraulic pliers allow you to crimp wires up to 10 sq. mm;
• In industrial production, a hand press is used. It is suitable for wires up to 240 sq. mm;
• hydraulic press with electric drive is used for cables up to 300 sq. mm.

Types of instruments

Press pliers with hinges increase the pressure of the tool, which makes the manual crimping process easier. Devices with a ratcheting mechanism are especially convenient. They prevent the instrument from unclenching until the procedure is completed.

You can watch how to crimp a wire without tools in this video:

Types of press jaws

The manual crimper is used for crimping non-insulated cable lugs, contact connectors, terminals and contact sleeves of various sizes. If a manual crimper has special blades (usually they are located where the handles are attached), then this tool can also be used for cutting cables and wires.

Electric pliers are a multifunctional tool for professional use. They can do almost any work with wires. Electric pliers are mainly used for cutting and stripping wires, but they can also be used to crimp uninsulated and insulated cable ends.

A crimper is a tool for crimping wire lugs, twisted pair cables, and connectors. It has two long handles (one or both can be movable) and a massive working part in the form of metal jaws, which have holes for cables.

When the handles are brought together, the jaws close and the cable connector is crimped using forceful pressing. Some models have a blade on the working part, which simplifies the work - no additional tools are required to cut the cable.

How to choose press jaws

The choice of crimping tool is determined by the cross-section of the wire. The larger it is, the more powerful the device should be. Human effort is not enough to create a tight and uniform pressure, even when using household tips.

Crimping of cable lugs is performed using one of the following tools:

• Press pliers of brands PK2 or PK2M - for manual use, suitable for wires with a cross-section of up to 10 sq. mm.
• Hydraulic pliers – designed for terminating cables up to 10 sq. mm.
• Press pliers for crimping terminals, brands PK1 or PK1M - similar to the first tool, but reinforced with long handles, due to this they are capable of crimping a wire up to 50 sq. mm.

More powerful devices, such as manual and hydraulic presses, are used in production. With their help, you can crimp wires with a cross-section of up to 30 sq. mm.

Hand press pliers for home use

Determination by magnet

Color matching is a reliable but not sufficient method of identification. The second step of independent experiments will be a test with a magnet. Chemically pure copper is classified as diamagnetic - i.e. to substances that do not respond to magnetic influence. If the material under study is attracted to a magnet, then it is an alloy in which the content of the main substance is no more than 50%. However, even if the sample did not react to the magnet, it is too early to rejoice, since often an aluminum base is hidden under the copper coating, which is also not magnetic (this can be eliminated by filing or cutting).

How to crimp wire lugs without tools

What to do if you don’t have special tools for crimping on hand or you just don’t want to buy them if you only need to crimp one or two tips?

Many, faced with this problem, resort to incorrect methods, which in the future only worsen the contact, without ensuring a reliable connection. They begin to flatten the tip with hammers, simply squeeze it in a bench vice, crush it with pliers, and press it in with a chisel. All these methods are incorrect and do not bring the desired result. After such amateur activity, poor contact is obtained with its further heating during operation.

Where to buy cable lugs for crimping

Before you go to the store, you should familiarize yourself with the options offered on the market in advance. The table shows prices for some cable lugs for crimping.

Photo Products Characteristics Average price, rub.

Pin sleeve insulated tip NSHVI2 2.5-10, 50 pcs Peredovik 26685

To choose a quality product, remember that each tip must have a specific wire. The discrepancy between these two elements most often leads to errors when performing crimping. You cannot use homemade tips or cut the sleeve into two parts to save money. We hope that our advice will be useful to you and help you make the right choice.

Distinctive Parameters

Tinned copper has high ductility and can be easily machined. It is this material that is used in electrical engineering for the manufacture of conductive cores of copper cables and braiding for military and civil products.

Let's try to find out the difference between tinned and untinned copper. The first option is more protected from external influences, since the wire is coated with a layer of tin. This metal protects the metal thread from any manifestations of corrosion, giving the material increased tensile strength. Tinned copper does not break when bent.