• SIGNA™ Hero 3.0T Service Methods
  • 5852800-8EN Revision 1.0
  • Object ID: 00000018WIA30F84C20GYZ
  • Topic ID: id_2008421 Version: 2.19
  • Date: Jun 7, 2021 2:40:46 AM

Crimping gradient cables

Information for correct lug crimping.

About this task

Note: An optional hydraulic crimping tool (T&B TBM6PCR-LI) has been bay tested to be safe at 200 G. This tool is available for purchase directly from the manufacturer (www.tnb.com). If choosing this option, also purchase the necessary crimping dies for the tool as specified above.
Important: These steps are general crimping procedure. There may be more specific information in the procedure that requires the crimping.

Procedure

  1. Make sure you have the correct crimping tool. The only qualified crimpers approved for use with the Thomas and Betts Color-Keyed® lugs are the Thomas and Betts model TBM5 or TBM5-S.
    Figure 1. TBM5-S crimp tool
    1Crimp tool
    2Tool creates diamond style crimp
  2. Identify the required lugs for your procedure. Consult the procedure for the correct lugs.
    Table 1. Available Lugs
    PictureGE part numberMFGMFG part numberColor bandDie number/ gaugeStud size
    5799023Thomas & Betts54155-TBPink42/1/0 AWG.500 inch
    5826292Thomas & Betts256-30695-886Pink42/1/0 AWG.500 inch
    5368384Thomas & Betts54105Blue24/6AWG.250 inch
  3. The crimpers and lugs in the kit are approved for DV field-terminated gradient cable installation:
    1. Crimper tool: Thomas & Betts TBM5 or TBM5-S
    2. Lugs: Use the lugs shown by the procedure.
    Figure 2. Lug feature identification
    1Terminal mating area
    2End bellmouth
    3Barrel (conductor crimp area)
    4Entry bellmouth
    5Brush inspection window
  4. Match the color on the lug to the color on the die.
    Note: The die may need to be switched when crimping a different colored lug (blue ground and pink or green lugs require different dies).
    Note: A crimping nest with more than one color band may be used to crimp Color-Keyed® connectors matching any of the nest color bands.
    Figure 3. Die
    1Die
    2Color code
    Table 2. Die color codes
    Die catalog numberDie groove colorEquivalent hex die code number
    13454Blue24
    13455Green37
  5. Examine the end of each wire that will receive a lug. Wire strands must be equal in length to allow full insertion into the barrel of the lug to the end of the bellmouth.
    Note: The clear plastic insulation can be removed from the stripped cable.
  6. Dry fit the correct lug on each cable and:
    1. Align the lug with the connection on the component.
    2. Mark the orientation of the lug with a marker. (This step eliminates the need to twist the gradient cable when attaching the lug.)
  7. While dry fitting the lug, make sure that the:
    1. Cable is fully inserted in the lug.
    2. Insulation is not charred or melted.
    3. Gap from the insulation to barrel is less than the width of a two-wire bundle.
    4. Insulation does not extend into the barrel of the lug.
    5. If these conditions are not confirmed, trim the cable or insulation as needed.
    Figure 4. Confirming gap and insulation clearance
    1Barrel
    2Insulation to barrel gap (must be less than #3)
    3Two-wire bundle diameter
  8. Put each lug in the die grooves of the crimping tool so the die is between the outer color-coded marks. Align each lug with the marks and crimp each lug onto the wires.
    Note: Use only the TBM5 or the TBM5-S supplied in GEHC Gradient Cable Tool Kit and the furnished T&B lugs.
    Figure 5. Lug placement on crimp tool
    1Wire
    2Die
    3Lug
    4Crimp tool
  9. As each crimp is made, make sure that:
    1. There are no loose wire strands. All conductor strands must be contained within the conductor crimp area. Zero loose strands are allowed.
      Figure 6. Good loose strand example
      Figure 7. Bad loose strand example
    2. The crimp is centered within the crimp area and the bellmouth is evident at each end of the conductor crimp area. No visible fractures or cracks should be present in the lug barrel or terminal contact mating area.
      Figure 8. Good strand depth example
      Figure 9. Bad strand depth example
    3. Strand damage is within allowable parameters. The allowable strand damage as defined by IPC/WHMA-A-620C section 3.2 for Class 2 is 6%. The number of damaged (scraped, nicked, or severed) strands in a single cable should not exceed this limit. The maximum number of allowable cut strands is limited to 6% (for a 1AWG gauge wire, the maximum number of damaged strands is 50).
      Note: Strands that are cut off and do not continue into the lug barrel should be considered a loose strand and noted as a defect.
      Figure 10. Example of 1 AWG with greater than 6% cut strands
    4. The gap is less than the diameter of a two-wire bundle from the barrel. For an example, see Figure 4.
    5. Proper crimp compressions were used on the 1 AWG and 6 AWG gradient cables. Reference the next step for details.
  10. Do a check of the lug crimp pattern.
    1. For 1 AWG gradient cable (X, Y and Z axis), green bands with the printed word GREEN and the number 37 appear on the lug. The single crimp compression is diamond shaped and embossed with the number 37.
      Figure 11. 1 AWG crimp pattern
    2. For the 6 AWG gradient cable (ground lead), blue bands with the printed word BLUE and the number 24 appear on the lug. The single crimp compression is diamond shaped and embossed with the number 24.
      Figure 12. 6 AWG Crimp Pattern