STOR W001 Assembly Cable Lug To PowerAmp A Cables Rev 4

1. Introduction ............................................................................................................................................
3
2. Required Materials and Equipment .......................................................................................................3
3. Method....................................................................................................................................................3
3.1. Stripping Sheath ..............................................................................................................................3
3.2. Application of Oxide-breaker. ........................................................................................................5
3.3. Positioning Cable Lug .....................................................................................................................6
3.4. Crimping Bimetal Cable Lug ..........................................................................................................7
3.5. Positioning Heat Shrink Sleeve.......................................................................................................9
Date: 07/07/2015 STOR-W001 Assembly cable lug to PowerAmp A Cables Rev 4.docx
Page 2 of 11
1. Introduction
This Instruction describes the method used to install Bi-Metal Cable lugs onto PowerAmp-A 450/750V
Cable. The recommended method is by means of Bi-Metal Cable Lugs, bolted directly onto equipment
bus bars or treaded terminal adaptors.
All the photographs in this installation instruction contain 240mm² PowerAmp A cable, however the
same procedure should be followed for all sizes of cable.
2. Required Materials and Equipment
• PowerAmp-A Cable (See Table 1 attached)

• Oxide Breaker Incore Article No. A12B OCG 1200
• Cable Lug (See Table 1 attached)
• Heat Shrink Sleeve
• Cable stripping tool
• Small paint brush
• Crimping tool
• Set of crimping dies
• Hot air gun or Gas Torch
Table 1 contains the article numbers of PowerAmp A Cables, Bi-metal cable lugs and the
recommended die sizes for each cable.
3. Method
3.1. Stripping Sheath
The CSP Sheath and EPR insulation should be removed, for a minimum length, according to the
values shown in Table 2, or as advised by the cable lug supplier. This length should be equivalent
to the internal length of the cable lug crimp barrel.
Photograph 1
Great care should be taken not to mark or damage the individual conductor wires during stripping.
Page 3 of 11
Photograph 2
Smoothly remove the sheath and insulation by pulling in a longitudinal direction and turning
slowly in the lay direction of the wire bundles.
Photograph 3
If disturbed during the removal of the sheath and insulation the lay of the wire strands should be
restored, as near as possible, to the original position.
Ensure that the separator tape (foil between conductor and insulation) is removed over the entire
length and circumference of the conductor.
Page 4 of 11
3.2. Application of Oxide-breaker.
Before applying an oxide-breaker, brush off oxide layer off the surface of conductor!
While the bimetal lugs already contain an Oxide Breaker, a further coating of A12B OCG 1200 paste should
be applied to the surface of the aluminum conductor. This paste prevents the formation of an insulating
aluminum oxide coating on both the conductor and cable lug surfaces and decreases the contact resistance.
Photograph 4
A simple paint brush can be used to apply the Oxide Breaker.
Photograph 5
Sufficient should be applied and distributed evenly over the entire conductor surface.
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Ensure surface of conductor is completely covered with the Oxide Breaker.
3.3. Positioning Cable Lug
The stripped conductor end is placed into the crimp barrel of the bimetal cable lug.
Photograph 6
Care should be taken to ensure that all wires of the conductor are within the crimp barrel.
Photograph 7
The conductor should be pushed into the Cable Lug until it touches the inside end of the crimp barrel.
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3.4. Crimping Bimetal Cable Lug
In order to make a good mechanical and electrical contact the barrel of the cable lug is physically
compressed around the conductor. This is done using a full cycle ratcheting crimp tool, which ensures the
crimp is fully completed before the cable lug can be released from the tool. Before starting, check that
both crimping dies are of the correct type/number, see Table 1 for recommended sizes.
Photograph 8
The first crimp should be made at approximately 5mm from the end of the crimp barrel closest to
the copper palm of the bimetal cable lug.
Page 7 of 11
Photograph 9
The second crimp should be made at a distance of approximately 2mm from the first crimp. The press-head
should be rotated approximately 30° to ensure that the alignment of the hexagonal crimps is staggered,
The third crimp should be applied a further approximately 2mm along the crimp barrel. The press-head
should be rotated back approximately 30° to align this hexagonal crimp with the first crimp applied.
Photograph 10
Photograph 11
When the crimp is completed there should be no sharp edges along the surface or trumpeting at the end of
the crimp barrel. In case sharp edges have formed during the crimping process these should be removed to
Page 8 of 11
avoid damage to the heat shrink sleeve. Any sharp edges can either be removed using a file or by flattening
with a hammer. If a hammer is used care should be taken not to cause any disfiguration to the lug.
3.5. Positioning Heat Shrink Sleeve
When the bimetal cable lug has been crimped onto the conductor a heat shrink sleeve should be applied.
The purpose of this sleeve is to prevent the ingress of moisture or dirt at the junction between the
insulation end and the back of the cable lug. The heat shrink sleeve contains glue, which melts and creates
a seal when heated.
A practical indication for the length of the heat shrink sleeve would be twice the length of the
cable lug crimp barrel. It should be positioned with one end flush with the end of the crimp barrel
closest to the copper section of the bimetal cable lug.
Photograph 12
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3.6 Shrinking The Heat Shrink Sleeve
When positioned the sleeve should be heated until it has been reduced to fit tightly over both the cable and
bimetal cable lug. The heat can be applied by means of a naked flame or a hot air gun. Care should be
taken not to overheat or burn the sleeve during shrinking. When using a naked flame only the outer yellow
section of the flame should come into contact with the sleeve. The heat should first be applied in the center
of the sleeve and from there towards both ends individually. Once the sleeve has been reduced to fit tightly
remove the heat source to prevent burning of the sleeve and further reduction which could cause splitting.
Photograph 13
Page 10 of 11
Photograph 14
Finished assembly
TABLE 1
Cable Type Connector Type Die Size Remarks

PowerAmp Bi-Metal Lug
6mm² A27A BMCL 0700/0701 Cu 95
10mm² A27A BMCL 0800/0801 Cu 95
16mm² A27A BMCL 0900/0901 Cu 95
25mm² A27A BMCL 1000/1001 Cu 95
35mm² A27A BMCL 1100/1101 MK20-C Hydr. Pomp:
50mm² A27A BMCL 1200/1201 MK20-C - Alfra DSP 120
70mm² A27A BMCL 1300/1301/1310 MK20-C Hydr. Press:
95mm² A27A BMCL 1400 MK25-C Cembre RHU 131
120mm² A27A BMCL 1500/1510 MK25-C
150mm² A27A BMCL 1600 MK30L-C
185mm² A27A BMCL 1700 MK30L-C
240mm² A27A BMCL 1800/1801 MK34L-C
300mm² A27A BMCL 1900/1901 MK38 3D ECW-H3D Press Head
400mm² A27A BMCL 2000/2001 MK46 3D ECW-H3D Press Head
In the article no. xx denotes the colour of the cable as follows:

BK = Black. BL = Blue. BN = Brown. GR = Grey. OR = Orange. YL = Yellow.
GY = Green/Yellow
TABLE 2
PowerAmp A Minimum
Cable Lug
Cable Stripping length
6mm² A27A BMCL 0700/0701 42mm
10mm² A27A BMCL 0800/0801 42mm
16mm² A27A BMCL 0900/0901 42mm
25mm² A27A BMCL 1000/1001 42mm
35mm² A27A BMCL 1100/1101 43mm
50mm² A27A BMCL 1200/1201 43mm
70mm² A27A BMCL 1300/1301 43mm
95mm² A27A BMCL 1400 60mm
120mm² A27A BMCL 1500 60mm
150mm² A27A BMCL 1600 60mm
185mm² A27A BMCL 1700 60mm
240mm² A27A BMCL 1800/1801 62mm
300mm² A27A BMCL 1900/1901 70mm
400mm² A27A BMCL 2000/2001 75mm
Page 11 of 11

STOR W001 Assembly Cable Lug To PowerAmp A Cables Rev 4

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1. Introduction ............................................................................................................................................

2. Required Materials and Equipment

• PowerAmp-A Cable (See Table 1 attached)

3.3. Positioning Cable Lug

3.5. Positioning Heat Shrink Sleeve

Cable Type Connector Type Die Size Remarks

In the article no. xx denotes the colour of the cable as follows:

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