Visual inspection of crimped connections Insulation crimping Wire crimping B or F-Crimp Contact twisted Mismatch Cross-section contact Insulation pierced 0.03 – 0.56 mm2 0.30 – 0.81 mm2 0.50 – 2.50 mm2 2.50 – 6.00 mm2 10° (AWG 32 –20) (AWG 22 –18) 0.25 +/- 0.15 mm 0.25 +/- 0.15 mm 0.40 +/- 0.20 mm 0.60 +/- 0.30 mm Crimp flanks hit upon the crimp contact base Insert slope (trumpet, bell mouth) must be visible! Insulation is enclosed and fixed The crimp flanks are closed Note: In case of double crimping with differing cross-sections and/or outer diameters, the smaller cable is ALWAYS at the bottom! Crimp too high Iso-crimp overfilled The twisting between the crimp zone and the contact body must be a maximum of 10°! Insulation pierced Position deviation Insulation crimp Crimp flank bent Overlapping crimp Mismatch Cross-section contact Individual strands are not enclosed in wire crimp – insertion error 3° 5° Crimp not closed Insertion slope allowed Crimp not filled Crimp is overpressed Crimp too low Insulation pierced Crimp too high Mismatch Cracks in crimp base and severe burr formation Dividing tab must be present! (max. 0.5 mm) Insulation is enclosed and fixed The crimp flanks “overlap” Insulation damaged Note: In case of double crimping with differing cross-sections and/or outer diameters, the smaller cable is ALWAYS at the bottom! Crimp too high Crimp flanks are closed, support each other and are uniformly curledt Insulation pierced Asymmetry: Max. material thickness Note: The same quality standards apply for processing single wire seals O or enclosed crimp Iso-crimp is “overpressed” Insulation is enclosed and fixed. The crimp flanks “overlap” one another Iso-crimp too large Insulation not enclosed Position of the conductor in the crimp contact Wire crimp is not closed and is overfilled Crimp flanks curl unevenly Mismatch: conductor cross-section contact Mismatch: conductor cross-section contact Min. half material thickness Burr height less than material thickness Conductor and insulation must be visible! Mismatch: conductor cross-section contact No damage to the insulation permissible! Pressure marks must be visible! Contact is not centred to the tool Burr height less than half material thickness Functional zone of crimp contacts Strands cut off or broken Dividing tab too long and deformed Contact functional zone damaged and deformed End of the conductor must be visible! Transition damaged Horizontal ± max. 3° Axial shift Cable inserted too short Cable stripped too short Strands are broken in the wire crimp The insulation is not stripped, but only inserted in the insulation crimp zone and crimped. The 30° deflection is applied without extraction force. Extraction force in accordance with DIN 46 249 Part 1, SEN 245010 and EN 60352-2: 2006 Always perform extraction tests with insulation crimp open! Individual wires break off irregularly beyond the insert slope = Test OK! The cable must not fall out! Individual wires break irregularly beyond the insert slope = Crimp too low! Wire crimp without cable Nominal conductor cross-section mm2 0.14 0.25 0.50 0.75 1.00 1.50 2.50 4.00 6.00 Extraction force (N) min. Nominal size (plug width) 2.8 2.8 2.8 2.8 2.8 4.8 4.8 4.8 4.8 4.8 6.3 6.3 6.3 6.3 6.3 6.3 6.3 Measuring crimping dimensions Nominal size 2.8 Nominal size 4.8–9.5 20 40 60 70 80 20 40 80 120 160 200 250 350 500 9.5 9.5 For different conductor cross sections the lower extraction force is definitive in each case.The extraction forces for the nominal size 2.8 arise from the lower material thickness. Excerpt: DIN 46 249 Part 1. Crimp too high! Note: It is not sufficient to simply measure the conductor extraction force, as it could have the same value for different compression levels! Inspection of the crimp dimensions is required! Extraction forces in accordance with SEN 245010: The SEN 245010 standard applies the most stringent QA requirements for a crimp connection in international comparison. Cross-section 0,75–50 mm2 –95 mm2 over 95 mm2 Extraction for 150 N per mm2 120 N per mm2 100 N per mm2 Pull-Out Force of Crimp Connections Testing has to be in accordance with Test 16d of IEC 60512. Wire Gauge mm 0.05 0.08 0.12 0.14 0.22 0.25 0.32 0.5 0.75 0.82 1.0 2 AWG 30 28 26 24 22 20 18 Pull-Out Force N 6 11 15 18 28 32 40 60 85 90 108 Wire Gauge mm 1.3 1.5 2.1 2.5 3.3 4.0 5.3 6.0 8.4 10.0 2 AWG 16 14 12 10 8 Crimp height Crimp dimensions and tolerances for the crimp contact under test are to be taken from the relevant processing specification! Pull-Out Force N 135 150 200 230 275 310 355 360 370 380 IEC 60760, Section 17 and IEC 61210, table 9, show the same values for validation of crimp connections. Crimp width Definition of insulation crimp height in accordance with DIN 41 611 Part 3 www.we-online.com Note: Crimp contacts with damaged, bent and deformed functional zones (snap locks etc.) must NOT be “straightened out” and must always be disposed of as “bad parts”! Note: Divider tab must be visible. Length max. 0.5 mm Cable stripped too long Anvil Measuring tip Copyright by KabelForum – All rights reserved! www.kabelforum.de DIE NECKARPRINZEN 999927. 0912.1‘.DD Cable inserted too far Vertical ± max. 5°