Crimping tools are essential in electrical installation and maintenance.
Using insulated terminal crimpers and non-insulated crimping tools correctly ensures reliable, durable electrical connections and improves work efficiency.
This guide details the step-by-step usage, practical tips, and safety considerations for both types of tools.
Selecting the Right Terminal and Wire Size
Choose insulated terminals that perfectly match the wire gauge. Using mismatched sizes can lead to poor crimps and unsafe connections. The insulation on the terminal should match the wire’s insulation thickness to maintain protective covering after crimping.
Stripping and Preparing the Wire
Strip the wire insulation to slightly longer than the metal barrel length of the terminal, typically about 1-2 mm longer. Twist stranded wires tightly to prevent fraying and ensure the wire end is neat.
Inserting the Wire into the Terminal
Fully insert the stripped wire into the terminal’s metal barrel so that no copper strands are exposed outside the barrel.
Crimping Procedure
Use the insulated terminal crimper with a ratcheting mechanism for consistent pressure. Place the terminal correctly into the appropriate die slot (which is usually color-coded). Squeeze the handles firmly until the ratchet releases, signaling a complete crimp.
Inspecting the Crimp
Check that the terminal is firmly attached without cracks or deformities, the wire does not pull out, and the insulation remains intact. Optionally, perform a pull test to verify mechanical strength.
Heat Shrinking (if applicable)
Some insulated terminals come with built-in heat shrink tubing. Apply heat with a heat gun to shrink the tubing securely around the connection.
Appropriate Terminal and Wire Selection
Non-insulated terminals expose the metal conductor, therefore selecting the correct terminal size for the wire gauge is crucial to ensure good electrical contact.
Wire Preparation
Strip the wire to the required length, taking care to avoid nicks or cuts in the copper wire. The wire must be clean and free from oxidation for optimal conductivity.
Insertion and Crimping
Insert the prepared wire into the terminal barrel fully. Use the non-insulated crimping tool, often a ratcheting or mechanical type, applying even pressure to compress the terminal without damaging the wire strands.
Tool Maintenance and Usage Tips
Check the crimping tool before use for cleanliness and wear. Properly maintain and lubricate moving parts to ensure consistent compression force. Avoid side loading or uneven pressure during crimping.
Quality Assurance
After crimping, inspect for secure attachment and no exposed strands outside the barrel. Use electrical continuity tests if necessary to verify connection quality.
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Mastering the use of “insulated terminal crimper” and “non insulated crimping tool” improves the durability, safety, and reliability of electrical connections. Providing detailed tutorials to customers not only assists them in achieving optimal results but also strengthens your brand’s professional reputation in the export market.
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“Insulated terminal crimper” is specifically designed to crimp terminals covered with insulating material, protecting the wire connection, while a “non insulated crimping tool” is used for terminals without insulation, focusing on tight metal-to-metal contact.
Match the crimper slot or die size to your wire gauge (AWG). Most crimpers come with labeled slots for different wire sizes to ensure a secure and reliable connection.
It’s best to use tools designed for each type. Insulated terminal crimpers provide protection and precise pressure for insulated terminals, while non-insulated crimpers ensure a firm metal connection on bare terminals.
A good crimp should be tight and secure, with no exposed copper strands. The terminal should not move or pull off easily. Visual inspection and a pull test are common methods.
Ratcheting crimpers provide consistent pressure and release only when the crimp cycle is complete, ensuring uniform crimps and reducing errors compared to manual crimpers.
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