Pressing al cable lugs
Aluminium has special properties meaning that precise steps have to be taken for its processing. The ideal steps for obtaining a clean connection are as follows:
- Remove the insulation from the aluminium conductor.
- Treat the bright finish ends of the conductor, for example, carefully with a knife or a wire brush to roughly remove the oxidisation layer and to produce a clean contact surface. Ensure that when cleaning there are no metal residues left on the conductor, as otherwise this can cause contact corrosion.
- Insert the conductor into cable lug or connector up to the full insertion depth of the sleeve. The compound flows out of the sides and creates an exclusion of air, which prevents re-oxidisation.
- You can now make the hexagonal or indent crimping using the suitable crimping tool. Single and multi-stranded sector shaped conductors must be rounded with a suitable round press insert prior to crimping.
- Finally, remove any excess compound.
Alternative markings are provided on aluminium cable lugs for narrow and wide crimpings. The advantage of the wide variant is that the number of crimpings required is halved. However, note that a suitably strong crimping tool must be used for this.
You can use Klauke pre-rounding dies for sector shaped conductors. Unlike for copper conductors, no sleeve has to be used for multi-stranded sector shaped conductors.