Contents
Crimping
Crimping
Crimping
Introduction
Overview contacts – tools
Crimping tools for wire end ferrules
Introduction – Crimping tools for other contacts
Crimping tools for other contacts
Pressing tools
Crimping tools for connectors
Crimping inserts
Insertion tool for twisted-pair cables
Crimp removal tools
Tools for polymer optical fibre (POF)
Cable tie tools
D.2
D.4
D.6
D.12
D.14
D.24
D.26
D.27
D.29
D.30
D.31
D.32
D
D.1
Introduction
Crimping
Crimping
D
After stripping, appropriate contacts or wire end ferrules can
be crimped to the cable end.
Crimping produces a reliable connection between conductor
and contact, and has more or less completely replaced
soldering.
Crimping describes the production of a uniform, nondetachable
connection between conductor and connecting element.
This should be achieved exclusively by the use of a high-quality
precision tool. The result is a safe, reliable connection in both
electrical and mechanical terms.
Weidmüller offers a wide product range of mechanical crimping
tools.
An integral ratchet mechanism with disengaging option
guarantees optimum processing quality. Crimp connections
produced with Weidmüller tools comply with international
standards and specifications.
The DIN EN 60352-2 standard recommends that tools and
contacts should come from the same manufacturer, since this
is the only way to ensure consistently high quality. Otherwise, it
is the user who is responsible for the quality. Weidmüller tools
are designed to fit with Weidmüller contacts and thus are in full
compliance with the DIN EN standard.
Crimping of wire end ferrule: Optimum crimp of different
cross-sections as an example
Examples for the visual inspection of a crimp connection with
manual and automatic crimping tools by Weidmüller:
The conductor insulation must be pushed into the plastic collar.
The ferrule sleeve must be completely filled by the conductor.
Depending on the cross-section, the conductor should protrude
approx. 0 … 0.5 mm from the ferrule sleeve.
Cut-away view:
0 … 0.5
Front view:
0.5 mm
2
0.75 mm
2
1.0 mm
2
1.5 mm
2
2.5 mm
2
4.0 mm
2
For cross-sections
6…50 mm
2
, the crimping
shape is approximately
the same.
Introduction
Faulty crimping connections due to incorrect combination
of cable and wire end ferrule
It is not possible for a tool to function reliably with every combi-
nation of conductor and crimping material.
It is possible that the standard requirements for the crimped
product can’t be achieved, although taken on their own, both
conductor and crimping material comply with the corresponding
standard. The individual production tolerances of conductor and
crimping material do not allow every conductor to be combined
with every contact.
The combination of conductors, crimping material and crimping
tool must be coordinated: this procedure is all the more difficult
given the large number of products on the market.
This means that the material must be defined and the crimping
result tested, ensuring that the test, and later on the tool, satisfy
the same conditions.
Faults which can occur during crimping:
Single conductor
squeezed off
Single conductor
pushed back
• Cracks along the sides and die impressions
• Splitting of the ferrules
• Asymmetrical crimping shape
• Extreme burrs formed along the sides
• Ferrule not filled by the conductor
• Single conductors pushed back protruding from the collar
• Single conductors squeezed off
• Plastic collar damaged by the crimping jaw
• Conductor insulation not pushed into the plastic collar
• Ferrule bent longitudinally after crimping
Formation of cracks at the sides.
Sides split open
Formation of cracks at the
impressions of the crimping jaw
Asymmetrical crimping shape
Burr formation on one side
Asymmetrical crimping shape
Burr formation on one side
Note:
The ferrule must not split open after it has been connected once in any
Weidmüller terminal corresponding to the conductor cross-section (with a torque
according to IEC 60947-1)
D.3
Crimping
D
Overview contacts – tools
Crimp contact
Crimp type
Description
Conductor crosssection
in mm
2
0.5…2.5
0.14…6
0.25…1.5
0.5…4
AWG
Crimping tool
Order No.
tool
9020000000
9014350000
9005990000
9012500000
9013650000
page
Crimping
with plastic collar
with / without plastic collar
20…14
26…10
24…16
20…12
24…10
Stripax Plus 2.5
PZ 6 roto
PZ 1.5
PZ 4
PZ 6 HEX
D.6
D.9
D.7
D.8
D.7
with / without plastic collar
0.14…6
Wire end ferrules
with / without plastic collar
0.25…6
24…10
PZ 6/5
9011460000
D.8
D
with / without plastic collar
0.5…6
20…10
PZ 3
0567300000
D.9
with / without plastic collar
6…16
25…50
10…6
3…1
PZ 16
PZ 50
9012600000
9006450000
D.10
D.11
Twin wire end ferrules
Twin wire end ferrules
0.5…1
0.5…4
0.5…2.5
0.5…4
0.5…4
0.5…4
6…16
20…17
20…12
20…14
20…12
20…12
20…12
10…6
24…12
24…22 /
20…17
PZ 1.5
PZ 6 HEX
PZ 4
PZ 6/5
PZ 3
PZ 6 roto
PZ ZH 16
HTF DFF
HTF ZRV
9005990000
9013650000
9012500000
9011460000
0567300000
9014350000
9013600000
9014140000
9014840000
D.7
D.7
D.8
D.8
D.9
D.9
D.10
D.23
D.23
Weidmüller DFF series
0.22…2.5
0.2…0.35 / 0.5…1
Stamped contacts
Weidmüller ZRV and MKF series
Weidmüller FEKO ZRV series
Weidmüller RSV and DSTV-HD Systems
0.2…2.5
0.14…1.5
2.5
24…12
26…16
14…12
HTF AFK 2.5
HTF RSV 16
HTF RSV 12
9201040000
9013560000
9013550000
D.23
D.23
D.23
Turned HD and HE contacts
4…10
0.14…4
12…7
26...12
26...10
16...7
CTX CM 3.6
CTX CM 1.6/2.5
CTIN CM 1.6/2.5
CTIN CM 3.6
9018480000
9018490000
9205430000
9205440000
D.18
D.18
D.18
D.18
Turned contacts
Turned HD. HE and HX contacts
0.14...6
1.5...10
D.4
Overview contacts – tools
Crimp contact
Crimp type
Bezeichnung
Description
in mm
2
AWG
Crimping tool
Order No.
tool
9012000000
9012020000
9012010000
9012410000
9012400000
9011990000
9006320000
9006370000
9006380000
page
HTG 58/59
D.21
D.21
D.21
D.21
D.21
D.22
D.22
D.22
coaxial connectors
HTG 59
HTG 174
HTX 138
HTX 188
coaxial connectors
CTX 500
CTX 501
CTX 502
insulated / non-insulated
connectors
insulated connectors
0.5…2.5
0.5…6
0.5…6
20…14
20...10
20...10
HTI 15
CTI 6
CTI 6 G
9014400000
9006120000
9202850000
D.16
D.15
D.15
non-insulated connectors
0.5…6
0.5…6
10…25
10…25
20...10
20...10
7…3
7…3
28…24
28…24
HTN 21
HTN 21 with end stop
CTN 25 D4
CTN 25 D5
TT 864 RS WE
TT 1064 RS WE
9014610000
9014100000
9006220000
9006230000
9008120000
9008190000
D.16
D.16
D.17
D.17
D.25
D.25
modular plug connectors
WE-plug (4, 6 and 8-poles)
WE-plug (4, 6 and 10-poles)
0.08…0.25
0.08…0.25
shielded WE-plug, system Hirose
0.08…0.25
0.08...0.25
28…24
28...24
TT 8 GH
TT8 RS MP8
9005640000
9202800000
D.24
D.24
SUB-D contacts
0.08…0.5
28…20
HTF SUB-D
9013260000
D.22
Other contacts and plugs
flat blade connectors and receptacles
0.1…1 (connec. width 2.8)
0.5…2.5 (connec. width 4.8)
0.5…2,5 (connec. width 6.3)
0.5…6 (connec. width 6.3)
27…17
20…14
20…14
20…10
HTF 28
HTF 48
HTF 63
CTF 63
HTX LWL
9013090000
9013080000
9013400000
9202860000
9011360000
D.14
D.14
D.14
D.14
D.19
fibre optic connectors
Station 1 (hexagon crimp):
3.15 / 6.0 H.-➝ 3.9
Station 2 (round crimp):
4.85 / 6.0 H.-➝ 5.5
HTX LWL
9011360000
D.19
IP67 connector
IE-CT-SC-GOF
IE-CT-LC-GOF
IE-CT-SC-POF
IE-CT-SC-GOF-P
9205320000
9205330000
9205340000
9205350000
D.20
D.20
D.20
D.20
D.5
Crimping
coaxial connectors
HTG 58
D.21
D
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