Brief on Low Voltage Cable Terminations

 

 

A cable termination is connecting a cable end to an equipment piece or another cable physically and electrically. Cable terminations are therefore devised and fitted for physical and electrical connection of two ends of a cable.

Physical requirements entail providing mechanical protection to the connection as well as offering security from environmental factors while electrical requirements pertain to material compatibility, carrying capacity of the current, voltage drop in connection etc. Some of the commonly used terminations are the wire-wrapping connections, crimp connections, soldered connections, loop connections and compression terminations.

Soldered connection involves soldering the cables’ like conductors together to form a termination that is low-resistant and physically secure. Varied solder lugs are available which enable to solder the wire or cable directly on to it in case of the standard types. This type of termination is not applied so often except in situations which involve the use of connectors that are of the rounded ‘military type’ variety.

In case of wire wrapping connections, a rectangular metal post is tightly wrapped around by an uninsulated solid conductor in a multitude of turns. The wrapping is done so tightly that a secured electrical and physical connection is made. However, this termination is not very commonly used for regular applications; it is more often found in applications involving multiplex panels or computers. Distribution boxes comprising telephone circuits adopt this cable termination method.

Crimp connections comprise connections that use terminals with tube-shaped openings on which cable conductors are kept. The tube is pressed mechanically applying significant force so as to wrap around the conductor tightly and form a connection. The procedure requires the use of a crimping tool which is specifically designed for the activity. Calibrated crimping tools are used for circuits involving nuclear safety and the procedure is conducted under strict supervision to guarantee a proper connection. Crimp connections come in varied sizes and find their way in control, instrument and power circuits.

In Compression terminations, uninsulated conductor is put inside a ‘box’ and a flat strap, screw or any like mechanism is used to compress the conductor and make the connection. This kind of connection is adopted in low-voltage circuit breakers.

Loop connection which is formed at screw terminals uses an uninsulated conductor that is wrapped below the screw’s head and about its trunk. A relatively cheaper form of connection, it is applied in applications where the connection would not be disconnected so frequently. The conductor loop goes in the clockwise direction similar to that of the screw tightening.

Heat shrink equipment like heat shrink tubes etc. plays an important role in cable terminations. Heat shrink terminations still remain the traditional means for connecting cables into transformers and switchgear as well as air insulated cable boxes and thus offer reliable performance in industrial applications. The applications may be required for indoors such as in substations or in external precincts such as pole mounted overhead lines. However, greater skill is required in heat shrink terminations to ensure that surface heating is even and consistent and this has led to the preference for cold shrink terminations in today’s times.