Overview - TNB.COM

1 Better method to install solderless compressionconnectors on power cableThe Thomas & Betts method of installing compression connectorson power cables is designed to provide a high degree ofreliability in electrical wiring. This method allows electrical workers to make installations withlittle effort and considerable savings in time. The Thomas & Bettsmethod is a simple three-step installing procedure that utilisesColor-Keyed connectors and dies with compression typeinstalling three steps First, the appropriate connector is chosen for the conductorsize Next, the proper installing die is selected by matching thedie colour to the connector colour Last, the die is installed in the tool, and the connector conductivity electrolytic copper Excellent electrical conductivity thanks to lowest electrical resistance,associated to superior tensile strengthTubular constructionNo seam, ensuring excellent mechanical propertiesElectro-tin platedEnhanced corrosion resistanceColour-coding according to the cross-section of the cable,Easy selection of the connector.

2 The die and the tool according by marking the connector with coloured rings and to the size of the cablewith the name of the colour Higher level of reliability Die-code engraved on the surface of the die Easy and reliable inspection SpecificationsAccording to DIN and ULAir compression by the T&B Method, the cross section looks like this,100% metal with virtually no air spaces. Before compression , a typical cross section of cable and connectorconsists of about 75% metal and 25% Color-Keyed system from Thomas & Betts tellsyou where to place the installing dieColor-Keyed connectors not only identify the correct installingdie to be used for positive compressions, but also indicate theproper placement of the die on the connector. This is done bythe coloured rings around the connector which match thecolour on the dies. compression is made between or on thesecolour bands. The colour name is also spelled on the connectoras an added means of die is positioned between colour bands for copper connectors andon the bands for aluminium dies form a solid, homogenous mass The Thomas & Betts method utilising compression tools withmatching dies forms the connector and conductor into a solid,homogenous mass to provide an optimum electrical bondbetween connector and conductor.

3 Color-Keyed dies are designed to produce a circumferential,hex- or diamond-shaped compression rather than a simpleindent. Precision dies are an integral part of the Thomas & Bettsmethod. Each die is designed so that all conductors receive the sameamount of compression force. The circumferential compressioncreates a large area of high pressure contact between cable andconnector which, in turn, assures high conductivity, lowresistance, and high pullout values which exceed features result in a permanent, low installed costconnection. You can install it, and forget product offeringTwo-way splices For copper cable 600V to 35kV 2 types: - standard barrel- long barrelLugs For copper cable 600V to 35kV Standard barrel 2 types: - one installing hole - two installing holesSee pages 326 to 329 for detailed information on standardproduct offeringSpecial & customised product offeringColor-Keyed : special lugs for special applicationsAngled, shaped and trimmedThomas & Betts can solve your difficult wire bending andterminating problems in confined power distributionpanels, switchgear and motor control enclosures.

4 We havethe design and production capability to deliver exactly thetype of lug you need, shaped the way you need. Straight, 45 and 90 angle Stacking or non-stacking Narrow tongue or standard Tin, silver, lead, nickel plated Thomas & Betts offer anextensive line of copper Color-Keyed lugs for flexible andsolid lug tongues are modified in several differentconfigurations to meet your exact needs: 45 and 90 bendangles, narrow tongues to fit into circuit breakers, offsettongues to stack two cables, and special stud hole drilling. These special configurations let you:1. run the cable directly to the bus bar with no bending,2. terminate into very narrow spaces, and3. utilise minimal bus bar specially designed lugs help you clean up yourcabling in crowded enclosures. Customised Color-Keyed lugsConnectors for Copper CablesAll customised lugs can be made to order. Minimum orderquantity: standard package quantity by cable size.

5 Consultyour Sales Office for price and delivery. SIZENOMINALNOMINALCROSS-CMAAWGDIAMETERDI AMETERSECTIONCIRCULAR MILS[inch][mm][mm2][cmil]4 : 1 kcmil = 1000 cmilUnit conversion table: AWG round wire size to diameter and cross-sectionWIRE SIZENOMINALNOMINALCROSS-CMAAWGDIAMETERDI AMETERSECTIONCIRCULAR MILS[inch][mm][mm2][cmil] conversion table: American bolt sizesUSMIN. HOLE DIAMETERMATCHING BOLT INBOLT SIZE[mm][inch]METRIC connectors provide high pullout values, are easy toinsulate, and provide a low resistance connection of highquality and low installed Information MaterialHigh conductivity wrought copperPlatingElectro-tin platedMetal barrelCopper tubeVoltage600V to 35kVMarkingColour reference for die and cable sizeTwo-way splice connectors for coppercable standard barrel 600 V to 35 kV EUROPEANCOLOURTOOLINGDIMENSIONSWEIGHTQUA NTITYCABLE SIZECABLE SIZEDIE CODEAE[mm2][mm][mm][kg/100][pieces]

6 54504# 8 # 6 # 4 # 2 AWG25 - # 1 kcmil200 Blue76 / kcmil500 tooling see pages 330 to 333 This represents a small part of the Color-Keyed range, please contact your Sales Office for additional product informationOrdering Information splice connectors for copper cable long barrel 600 V to 35 kV applicationsTechnical Information MaterialHigh conductivity wrought copperPlatingElectro-tin platedMetal barrelCopper tubeVoltage600V to 35kVMarkingColour reference for die and cable EUROPEANCOLOURTOOLINGDIMENSIONSWEIGHTQUA NTITYCABLE SIZECABLE SIZEDIE CODEAE[mm2][mm][mm][kg/100][pieces]54804 # 8 # 6 # 4 # 2 AWG25 - # 1 kcmil200 Blue76 / kcmil500 kcmil750 kcmil1000 tooling see pages 330 to 333 This represents a small part of the Color-Keyed range, please contact your Sales Office for additional product informationOrdering Information hole lug for copper cable Standard barrel 600 V to 35 kV applicationsTechnical Information MaterialHigh conductivity wrought copperPlatingElectro-tin platedMetal barrelCopper tubeVoltage600V to 35kVMarkingColour reference for die and cable sizePRODUCTUSAAPPROX.

7 STUD CODEABCD E FSIZECABLE SIZEEQUIVALENT[mm2][mm][mm][mm][mm][mm][ mm] [kg/100][pieces]54132# 8 AWG83/8M # 6 AWG133/8M # 4 AWG213/8M # 2 AWG25 - 341/2M # 1 AWG421/2M AWG531/2M AWG671/2M AWG851/2M AWG1071/2M kcmil1251/2M Weld 1/2M kcmil1501/2M Weld 1/2M kcmil1755/8M kcmil2005/8M Weld 1/2M kcmil2505/8M Weld 5/8M kcmil3005/8M 16 kcmil3505/8M kcmil3755/8M tooling see pages 330 to 333 This represents a small part of the Color-Keyed range, please contact your Sales Office for additional product informationOrdering Information hole lugs for copper cable Standard barrel 600 V to 35 kV applicationsTechnical Information MaterialHigh conductivity wrought copperPlatingElectro tin platedMetal barrelCopper tubeVoltage600V to 35kVMarkingColour reference for die and cable sizePRODUCTUSAAPPROX. STUD E F HCABLE SIZEEQUIVALENTCODESIZE[mm2][mm] [mm] [mm] [mm] [mm][mm][mm] [kg/100] [pieces]256-30695-1157# 8 AWG6 - 83/8M # 6 AWG10 - 133/8M # 4 AWG20 - 253/8M BE# 3-2 AWG25 - 351/2M BE# 1 AWG401/2 M AWG501/2M BE2/0 AWG701/2M BE3/0 AWG80 - 951/2M BE4/0 AWG100 - 1201/2M BE250 kcmil1251/2M BE300 kcmil1501/2M BE350 kcmil170 - 1851/2M BE400 kcmil2001/2M 12 Blue76/80 BE500 kcmil2501/2M BE600 kcmil3001/2M BE750 kcmil4001/2M 12 Black106H tooling see pages 330 to 333 This represents a small part of the Color-Keyed range, please contact your Sales Office for additional product informationOrdering Information Ref.

8 : TBM25S Fixed die tool, with rotating head and 5 nests For Color-Keyed copper tube lugsand splicesfrom:6 to 35 mm2 Shure-Stake mechanism Length: 220 mm Weight: 430 gStandard hand toolProduct Ref.: TBM5S Large hand tool with interchangeable dies For Color-Keyed copper tube lugsand splicesfrom: 8 AWG to 250 kcmil (= to mm2) in the case of copper cables Incorporates the Shure-Stake mechanism:once the pressing has commenced, the tool can be re-opened onlyafter successful completion of the crimping cycle, ensuringa correct crimp every time Furnished complete with carrying case and 5 installing dies(Product Ref. 13454, 13455, 13456, 13457, 13458) Dies are colour-coded and die-code embossed Tool length: 650 mm approx. Tool weight: 3kg approx. For die selection see table belowDies for TBM5 and TBM5S Multi-nest dies, to cover a wire size range from: 8 AWG to250 kcmil (= to mm2) in the case of copper cables Each nest is colour-coded and die-code embossedLarge hand toolsOrdering Information: dies for TBM5 and IDENTIFICATIONNEST IDENTIFICATIONCOPPER WIRE SIZECOPPER WIRE SIZECOLOUR-CODEDIE-CODEUSACONVERSION TO METRIC CROSS-SECTION[mm2]red218 : 2 other dies (Product Ref.)

9 13457 and Product Ref. 13458) are available, but for aluminium wire sizes onlyProduct Ref.: TBM5 Same specifications as Product Ref. TBM5S but does notincorporate the Shure-Stake Ref.: TBM8S Large hand tool with interchangeable dies For Color-Keyed copper tube lugsand splicesfrom: 8 AWG to 500 kcmil (= to mm2) in the case ofcopper cables Incorporates the Shure-Stake mechanism:once thepressing has commenced, the tool can be re-opened onlyafter successful completion of the crimping cycle, ensuringa correct crimp every time Furnished complete with carrying case and 8 installing dies(Product ref. 13461, 13462, 13463, 13463, 13464,13465,13466, 13467, 13468) Dies are colour-coded and die-code embossed Tool length: 650 mm Weight: kg For die selection see table belowDies for TBM8 and TBM8S Multi-nest dies, to cover a wire size range from: 8 AWG to500 kcmil (= to mm2) in the case of coppercables Each nest is colour-coded and die-code embossedLarge hand toolsProduct Ref.

10 : TBM8 Same specifications as Product Ref. TBM8S but does notincorporate the Shure-Stake mechanismOrdering Information: dies for TBM8 and IDENTIFICATIONNEST IDENTIFICATIONCOPPER WIRE SIZECOPPER WIRE SIZECOLOUR-CODEDIE-CODEUSACONVERSION TO METRIC CROSS-SECTION[mm2]red218 : 1 other die (Product Ref. 13464) is available, but for aluminium wire sizes Ref.: TBM14M Self-contained hydraulic tool with colour-codedinterchangeable dies For Color-Keyed copper tube lugsand splicesfrom:6 to 450 mm2 Incorporates the Shure-Stake mechanism:once thepressing has commenced, the tool can be re-openedonly after successful completion of the crimping cycle,ensuring a correct crimp every time Swivelled C - shaped head rotates 180 Complete with carrying case Weight: Output pressure: 14 ton For die selection see table page 333 Hydraulic tool headProduct Ref.: TBM15i Hydraulic tool head with interchangeable dies For Color-Keyed copper tube lugsand splicesfrom: 6 to 500 mm2 New longer, slimmer profile allows easier access intotight spaces Wider jaw opening eases crimping of larger connectors Available with an insulated head Supplied in a carrying case in steel Dies to be ordered separately Output Force: 15 tons (nominal) Operating Pressure: 10,000 psi (nominal) Tool weight.