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Electrical connection systems

Electrical connection systems
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Electrical connection systems

Product catalog summary
Introduction: This document serves as a comprehensive guide on tubular cable lugs and connectors, focusing on the blue connection® system for compacted multi-stranded conductors. It covers specifications, material details, tool application charts, and product benefits.
Tubular Cable Lugs and Connectors: The document details specifications for copper tubular cable lugs and connectors, including dimensions, material (copper according to EN 13600), and surface treatment (tin-plated). The blue connection® system is highlighted for its secure fit and efficient crimping without additional sleeves.
Tool Application Chart: A detailed chart is provided for selecting appropriate crimping tools for different cable lug sizes and types, including mechanical, hydraulic, and battery-powered tools compatible with the blue connection® system.
Product Benefits: The blue connection® system offers reduced material costs, fewer crimps, and enhanced safety due to precise fitting and vibration-proof design. It is tested to IEC 61238, part 1, ensuring high stability and reliability.
Material and Design: High-quality electrolytic copper is used for consistent precision and safety. The design includes a chamfer for easy conductor entry and burr-free edges, enhancing ease of use and reliability.
Additional Features: Optional features include inspection holes for checking conductor positions and various angle versions for specific applications.
Key Data: Detailed tables with dimensions, weights, and part numbers for various cable lug sizes are included, ensuring easy selection and ordering.
Conclusion: Klauke's blue connection® system provides a modern solution for electrical connections, ensuring safety, efficiency, and cost-effectiveness.
Specifications and Applications: Klauke's products are designed for high-quality requirements and international standards, suitable for applications like power supply, transportation, and railway technology. Custom solutions are also offered.
Material and Processing: Cable lugs are made from copper according to EN 13600 and are tin-plated for corrosion protection. The annealing process enhances material properties, reducing crimp force and tool wear.
Product Range: Various types of cable lugs are listed, including standard, fork type, and angle tubular lugs, with specifications for different cross-sections and bolt sizes.
Key Data from Tables: Tables provide detailed dimensions, weights, and part numbers for different cable lug types, facilitating product selection.
Nickel and Stainless Steel Tubular Cable Lugs: Nickel lugs are heat resistant up to 650°C, suitable for high-temperature environments. Stainless steel variants are heat resistant up to 400°C and compliant with food industry standards.
Specifications and Applications: These lugs cover industrial and shipbuilding applications, available in nominal cross-sections up to 95 mm².
Product Characteristics: Stainless steel lugs feature a flat contact surface and precise end machining for easy cable insertion.
Tool Application: Crimping tools for nickel and stainless steel lugs are available, with options matching the nominal cross-section of the lugs.
Copper Compression Cable Lugs to DIN: These lugs conform to DIN 46235 standards, available in cross-sections up to 1000 mm², with crimp markings for correct crimping.
Benefits and Features: Klauke's range includes DIN compression cable lugs and connectors, designed for easy crimping and extended tool life.
Aluminum Compression Cable Lugs and Connectors: Designed for full tension connections of aluminum conductors, with materials like E-Al and AlMgSi 1w, and nominal cross-sections from 16 mm² to 300 mm².
Procedures: Compression joints are filled with contact grease for optimal crimp results, with crimp markings for correct crimping.
Tools and Applications: A comprehensive tool application chart details suitable crimping tools for various cross-sections and materials.
Recommendations: For underground connections, protection against moisture is recommended, such as using cast resin sleeves.
Key Data from Tables: Tables provide detailed dimensions, part numbers, and crimping requirements for various cable lugs and connectors.
Crimping Tools and Cable End-Sleeves: The document details various crimping tools and cable end-sleeves, including specifications, procedures, and recommendations for effective use.
Crimping Tools: Tools are categorized by type, including mechanical, electrical, pneumatic, hand hydraulic, battery-powered, and hydraulic systems, with specific crimp profiles.
Cable End-Sleeves: Made from high-quality electrolytic copper, available in insulated and non-insulated types, compliant with DIN 46228 standards.
Key Features: Features include heat resistance up to 105°C, easy-entry insulation, and high-tensile strength due to grooved profiles.
Applications: Suitable for electrical connection systems for fine and superfine stranded conductors, and automated cable harness processing.
Assortment Boxes: Available in metal and plastic, designed for storing and organizing connectors and tools, with options for customization.
Key Features: Products are designed for durability and ease of use, with features like stackability and secure locking mechanisms.
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Catalog excerpts

Electrical connection systems-1

Electrical connection systems Product group index Tubular cable lugs and connectors blue connection® - Cu 24 Tubular cable lugs 26 Tool application chart 29 Copper tubular cable lugs and connectors - Cu 30 Tubular cable lugs 32 Angle tubular cable lugs 36 Insulated tubular cable lugs and connectors 44 Tubular cable lugs and connectors for fine stranded conductors 47 Tubular cable lugs and compression joints for solid conductors 51 Tubular cable lugs for switchgear connections 54 Tool application chart 55 Tubular cable lugs and connectors - nickel, stainless steel 62 Stainless steel tubular cable lugs and connectors 64 Tubular cable lugs and connectors - nickel 66 Tool application chart 68 Copper compression cable lugs and connectors to DIN 70 Compression cable lugs acc. to DIN 46235 72 Angle compression cable lugs 74 Compression cable lugs, special type 77 Compression joints acc. to DIN 46267, part 1 and similar versions 79 Tool application chart 84 Terminals, connectors and pin terminals to DIN - Cu 86 Insulated solderless terminals 90 Solderless terminals, fork and pin type 92 Insulated solderless terminals for meter connections 94 Tool application chart 97 Sleeves for compacted conductors and sector-shaped conductors - Cu 100 Aluminum compression cable lugs and connectors to DIN 106 Compression cable lugs acc. to DIN 46329 and similar versions - Al 108 Compression joints acc. to DIN 46267, part 2 and similar versions - Al 110 Reduction compression joints -Al 112 Compression joints, full tension - Al 115 Compression cable lugs and connectors for Al/St cables DIN EN 50182 - Al 116 Tool application chart 118 Aluminum/copper compression cable lugs and connectors 122 Compression cable lugs - Al/Cu 124 Compression joints - Al/Cu 126 Tool application chart 130

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Electrical connection systems-2

Clamps and screw connectors Punched cable lugs - Cu Screw connectors with soldering hole - CuZn Parallel groove clamps for tap off connections - Cu Screw connectors for street lighting - CuZn Screw connectors, high resistant aluminum alloy Compact tap connectors, high resistant aluminum alloy Tool application chart Electrical connection systems Product group index Cable end-sleeves acc. to DIN 46228, part 1 and part 2 154 Insulated cable end-sleeves acc. to DIN 46228, part 4 and similar versions 157 Insulated cable end-sleeves for short circuit resistant conductors 162 Insulated twin cable end-sleeves...

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Electrical connection systems-3

Simple. Safe. Efficient. blue connection® – because modern cables have narrower diameters Modern compacted multi-stranded conductors are up to 15 percent thinner than comparable predecessors. At the same time, savings are often made on sheathing and insulation. Here, conventional tubular cable lugs and connectors usually have too much play - a considerable safety risk which has to date necessitated additional sleeves for compacted conductors. Klauke has developed blue connection®, a special connection system for compacted multi-stranded conductors to VDE 0295 Class 2. Its copper tubular cable...

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Electrical connection systems-4

Only blue fits exactly! Cable lug Simple. Safe. Efficient. Cable lug with blue crimp info + blue crimping die + blue crimping tool = blue connection® ■ Simply assign and crimp. ▸ Perfect fit on compacted conductors to VDE 0295 Class 2. ▸ Simple assignment of crimping tool/crimping die through colour-coding system. ▸ Existing tools with replaceable crimping dies can continue to be used with blue connection® products. Benefits: ▸ Crimping of compacted conductors without additional sleeves. ▸ No investment in new tools, only the crimping dies are replaced. Safely connected. Manufacturer’s designation...

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Electrical connection systems-5

Electrical connection systems Tubular cable lugs and connectors, blue connection* - Cu Tubular cable lugs, blue connection®, Cu

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Electrical connection systems-6

Electrical connection systems Tubular cable lugs and connectors, blue connection® - Cu Tubular cable lugs, blue connection®, Cu Nominal cross section mm² 10-300 mm² IEC tested * = Also available in small handy packs Tools: see chart page 29

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Electrical connection systems-7

Electrical connection systems Tubular cable lugs and connectors, blue connection* - Cu Butt connectors, blue connection®, Cu ► For compacted multi-stranded conductors to VDE 0295 Class 2 ► Accurate assignment of crimping tool/crimping die through colour-coding ► Less crimpings due to max. crimping width ► Reduced costs due to compact dimensions ■ Processing takes place without the use of additional sleeves ■ Annealed material optimises material and crimping properties ■ Precise end machining for easy cable insertion Order info ■ Now also available in handy plastic boxes for smaller requirements,...

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Electrical connection systems-8

Electrical connection systems Tubular cable lugs and connectors, blue connection® - Cu blue connection ࡯ Tool application chart Tubular cable lugs and butt connectors blue connection© Crimping tools Crimping range corresponds to nominal cross-section mm² Crimping head/ Mechanical Adapter crimping tools Tool type mechanical, electrical, pneumatic, crimping tools with interchangeable dies/heads Hand hydraulic crimping tools Battery powered crimping tools Hydraulic crimping systems Hydraulic crimping heads Crimp profile Page (Tool)

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Electrical connection systems-9

Safe connections to Klauke standards. Copper tubular cable lugs and connectors for all applications. Safe electrical connections are crucial. Power outages caused by faulty cable connections can cause severe damage. The power supply is interrupted. Production comes to a stand-still. Traffic is disrupted. Tubular cable lugs and connectors from Klauke meet the highest quality requirements and satisfy international standards. Traditional applications are power supply, transportation, trade and industry, as well as building installation and railway technology. We also develop and produce tailor made...

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Electrical connection systems-10

■ Connections with system for every application. ▸ Products to Klauke standards in various designs and shapes. ▸ To international standards such as IEC, UL, DNV and German Lloyd. ▸ Solutions for cables with compacted round conductors, cables with sector-shaped conductors and to suit individual requirements. ▸ Plus all corresponding manual and hydraulic crimping tools. Benefits: ▸ The right products for every installation scenario. ▸ Highest flexibility for connecting cables. ▸ Standards-compliance permits international application. ▸ A single source for everything – from cable lugs to tools. ▸...

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*Prices are pre-tax. They exclude delivery charges and customs duties and do not include additional charges for installation or activation options. Prices are indicative only and may vary by country, with changes to the cost of raw materials and exchange rates.