Crimping Wires: Crimper Tools Used to Crimp Tiny Wires to HUGE CONDUCTORS!

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00:00 - Intro
00:16 - Lets Talk About Crimping (Small Wires)
03:40 - Larger Conductors Connections
04:34 - Crimping Tools
10:11 - ABB Testing Facility
In today's Electrician U video, we dive deep into the world of wire crimping, exploring various methods from simple butt splices to blades, and even high-grade connectors for larger conductors. 🛠️ Special thanks to our sponsor, ABB, who gave us an exclusive tour of their testing facility to showcase their state-of-the-art Color-Keyed® crimp style lugs and crimping tools.
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ABB's Color-Keyed® system takes crimping to the next level. Comprised of 99.9% pure, oxygen-free copper, their lugs are designed for accuracy and reliability. The color-coding ensures that you're using the correct die with the appropriate lug, leading to high-quality crimps that exceed both IEC 61238-1 and UL standards. What sets them apart is the circumferential compression they offer, creating a large area of high-pressure contact between the cable and connector for superior conductivity and pull-out values. 🌈🔩
We'll cover a range of crimping tools in this video, starting with basic hand tools featuring crimping mechanisms, progressing to battery-operated devices like those produced by ABB for use with their Color-Keyed® lugs, and finally taking you through hydraulic crimping tools essential for working with larger conductors. 💪🔋
At ABB's testing facility, we witnessed firsthand the rigorous testing procedures these crimp connections go through. From weight-based swirling tests and pull-apart machines to corrosion assessments, these lugs are put through the wringer. The highlight? Running a staggering 1500 amps of fault current through one of their terminations. The wire glowed red-hot, but the termination held its ground! 🔥💪
Don't miss this comprehensive look into crimping solutions that are both tradesmen-approved and meet the high standards of corporate innovation. Special thanks once again to ABB for their hospitality and for providing the tools that make this work possible.
#powerconnections #colorkeyed #colorkeyedsystem #ABB #installationproducts

[@deepbeing2629]

Hey Dustin- would love a video on dimmer switches; i.e. replacing dimmer switches, trouble shooting, which dimmer to use, why a dimmer switch can blow out without tripping the breaker, etc. Thanks for all the great content!!

[@davethebritdude9047]

Great show as always. I’m probably going to show my age now, no longer 21. I first used hexagonal crimping tools back in the late seventies/eighties. I think that was before ABB were formed.

[@henrystefanov5873]

You're right, hex crimps existed before ABB formed. Thomas and Betts pioneered crimp-on connectors and hex crimps, but ABB bought Thomas and Betts in 2012. So the people and factories of the original T&B still exists but under the ABB name, which is why you hear ABB now instead of Thomas and Betts.

[@xabbit0508]

Thank you for the hand tool information. Im loking for some small upgrades to my tools

[@MrP0EP0E]

I've been wondering when the next video was coming. I feel like it's been months..Thanks for all the hard work.

[@Boraxo]

2 good crimpers to check out, Klein Tools 3005CR Ratcheting Crimper and a HF Hydraulic Crimping Tool 64044

[@PhinAI]

Excellent! In an industrial setting, generally, our preferred crimping system is Thomas & Betts. I didn't know they were bought out by ABB.

[@windward2818]

Greenlee has a 6 Ton Hex Bottoming color coded die system using the EK622LX and EK628LX Battery Operated crimpers and the K22 series dies for both copper and aluminum stranded cable. A bottoming circumferential die (circular), like the Burndy bottoming W-Dies for copper, are also very strong and they have a proven track record in the industry for the USA. I prefer the color coded lugs from Panduit over both Burndy or T&B (now ABB) for 250 kcmil and smaller. Burndy I would say has the largest selection of lugs available from one manufacturer.

[@Robnord1]

At 5:30 that's an improper crimp and you probably know it Dustin. As a Marine and RV electrical specialist, I do it also(but never put the stake on the split of the terminal barrel because it offers less strain resistance). If you choose to demonstrate using what the industry calls an 'improper method' such as staking insulated terminals, it may be nice to tell exactly *why* you're doing that, and what the 'proper' but less effective/practical method actually is. My 2 cents.

[@thorritz8520]

Thanks for going over this I really enjoy your videos as i learn a ton of information. Thank you

[@apertureonfirephotography4795]

Our propress for plumbing is also a hex crimp. Works fantastic and well designed.

[@stacybehrens7152]

All the hand tools shown are quick and dirty field tools. Serviceable to be sure but do not make high quality crimps. Most terminals have specialized crimp tools designed specially for the terminal. Some quite expensive unfortunately. Most terminals have mfg recommended crimp height+width with a typical tolerance of +/- 0.002”. Basically impossible to achieve with a pair of lineman’s pliers. The crimp specs maximize both crimp strength and electrical performance. The specialty crimp tools might be overkill for basic applications but if maximum reliability and/or significant quantities (many thousands) of a terminal are involved they can be worth then investment. Also there are multi-purpose crimping pliers which while not a precise, are useful for more applications and produce a far better crimp than a set of strippers or lineman’s pliers and are much more reasonably priced.

[@ecospider5]

I did a couple DIY cables years ago. $1 jumper cables at a garage sale cut into 2 foot lengths. Copper pipe that fit over it for a crimped end with the copper pipe pounded flat and drilled. I didn’t have a crimper for 4 gauge wire. But my garden shears had a hinge with 4 sides. It squished the copper pipe and I couldn’t pull it off and they didn’t overheat so I called it good. Yes it was an ugly rhombus shape. But it is still holding after 2 decades. I have only used them 10-15 times for a couple days.

[@AnonYmous-yi4zy]

Are there NEC requirements regarding using listed crimp connectors or crimp tools? Should people be using a listed ratchet crimper for the red and blue ring terminals and such?

[@henrystefanov5873]

Yes! Each connector and crimp shape is different. Agency listings like UL and CSA require the tool AND connector both be listed together. Using a random tool with a random connector can create a bad connection, the safest choice is to pair the manufacture recommended crimp tool with that manufacture's connector. There's actually a lot of engineering that goes behind a crimping die.

[@ibrahimkesetovic7869]

Really so much info's and now I feel like a nerd...😅😊 I'm Electricuan in Germany for over 2 years and I worked in few fields... ABB, Schneider Electric are the most popular brands that are being requested by end-user to use their products in for ex. Fuse Box or ABB KNX (Smart Home)...so on... what I only didn't see it here in the vid' and you didn't cover tema is... so called in Germany ,,Conductor Paste"...which I saw it recently being all over the place where I worked on a new buildings with new electrical installations & new Main Lines Power Supplay...so, before putting on any type of connector I saw other older collegues put the conductor paste on the end before putting connector & crimping it!... kind of I see it as an advantage cuz' Main Powerlines for a bigger building require bigger cables by standard and any of those heavy duty cables when they are peeled...it look like mission impossible to fit on the end of this big butt cables connector to crimp it... so,...it goes a bit smooth when used with conductor paste...some people do & some not...so I guess it's not yet full standard. 😅😊 Would like to hear your opinion...Amazing Content! Love it! ❤😊

[@legionofanon]

Is the paste you are talking about the same as the aluminum anti corrosion paste for aluminum conductors? I'm seeing more and more recently that it's a code requirement (at least in the usa) to use it before installing a conductor into a lug connection

[@eflores200683]

Great video....

[@perryjones6803]

Cool stuff

[@mak4374]

Very good info, very nicely presented. Thank you. Oh, and ALL men NEED the battery operated crimpers even for the 24 gauge crimps...well, maybe not the hydrolic, I mean we are not weird or something... :)

[@PSwayBeats]

Please do a learning course for the Chicago or Midwest area

[@FishFind3000]

He hasn’t ever operated over here so he knows nothing about our rules.

[@Fraxinus23]

What are the titles of the books in the background? They look interesting.

[@lyfandeth]

If you make a "divot" that's properly called STAKING a fitting. CRIMPING is always supposed to completely surround and evenly apply pressure.

[@TheTubejunky]

It was an fault test. It helps define current density on conductors.

[@Weasel_NM575]

Whats the link for the cordless crimper?!

[@jesusdelgado8487]

We crimp 1000kcmil with makita battery crimpers

[@gabrielM1111]

Hi bro. Im in my 40s and looking for a career change. I always had an interest in electrical work. Im a pretty good diy handyman. How lomg of and type of school would i need. And how many years total until i can earn a good salary or be an independent licensed electrician? Thank you

[@tonytango6676]

I do believe that hydraulic fittings also have a hex crimp.😊

[@Struthio_Camelus]

The plumber's Pro-Press is six-sided too.

[@donpenning7172]

What about heat or load cycling

[@johnwilleford7715]

Weather it's a butt splice, fork, spade or something else all of the insulators are flared on the end, why? Why is there even insulators on them because they are somewhat damaged when you crimp them. Just something I have been curious about.

[@henrystefanov5873]

The flaring is so the wire's insulation can fit inside of the connector's insulation opening. You don't want wire strands visible outside of the insulation opening as that would defeat the purpose of an insulated connector. As for the damage you see after crimping.. that doesn't sound right. Insulators should not crack or break after crimping. Sounds like either cheap terminals or the wrong crimp tool is being used.

[@johnwilleford7715]

Thanks, Henry. I assume the gap / space between the wire insulation and the connector insulator makes no difference as long as the wire is fully in the connector?

[@mmendez123459]

You used a non insulated crimp on an insulated fork connector

[@Robnord1]

Yes he did. So do I. Since this is a video with a pro explaining the 'right way' to do things, that was a surprise to me that he didn't explain why he ignores the correct way. Also, when I do use a staking crimp (improper) on an insulated terminal, the stake should never be on the split because it will lack strength if the wire is pulled.

[@alphasaiyan5760]

First ! 👍🏼

[@JohnThomas-lq5qp]

Hated when ABB purchased the best maker of sta kins, crimp lugs, ty rabs etc maybe 10 years ago. ( T & B ). I used my dads T & B TBM5 crimper for 50 years and donated it to the place I retired from. Crimped thousands of #8 guage to 4/0 wires wuth it. Found ABB the worst company for VFD tech support. When I called them to only ask one question they gave me the run around and wanted to know why I needed an answer. Took the POS two weeks and 3 ir 4 e mails to finally tell me how to find DC Buss voltage on several of thier 18 pulse drives that we had no manuals.

[@inothome]

I thought the re-upload would have the correct insulated crimp.... Not to mention the whole crimp on the split or opposite the split on un-insualted lugs, nor the proper crimping tools to match the crimp.

[@nathaniel5208]

I am interested in being a Sponsor please reach out to me so we can Discuss further thanks

[@4dchessplayer516]

When you are going bald and decide to comb your hair forward instead of back..... shave it man.

[@rudispruell883]

Dude! That is Dustin's hair on Dustin's head the way Dustin wants it. You can do with your hair on your head however you want to. If seeing Dustin's hair bothers you, scroll away! And, wtf does that have to do with electricity?! ps- Dustin, you look good.

[@FishFind3000]

@@rudispruell883it looks awful. 😂

[@backroadcamry1467]

Amen brother. Murica

[@Struthio_Camelus]

Why don't we just enjoy Dustin's content and not worry about external appearances? This ain't Hairdresser U.

[@armandorojo4113]

That was not only uncalled for and unnecessarily but out right rude!

[@tolydukhovny682]

excellent overview! the hex line is nice. the only two items in my opinion that have to be legislated out are aluminum cables and solid cables. thanks for the video!