Only blue fits exactly! - Gustav Klauke GmbH

www.klauke.com
Only blue fits exactly!

Gustav Klauke.
The connecting technology specialist.
Rely on connections with system.
As a world leading supplier of connecting materials and crimping and cutting tools for
electrical engineering, we at Klauke claim to offer you the optimum solution at any time.
To do so, we continuously monitor the market and develop, time and time again, innovative
products that systematically simplify and optimise your day-to-day work.
With over 130 years of expertise, highly-qualified employees and the latest production
facilities, we also satisfy the highest quality requirements as confirmed by numerous
awards and certifications.
Benefit now from our single-source, expert service and use all the advantages of our new
professional connection system: blue connection.
2

Advice
Backed by long-standing experience in
connector technology, we have all the
essential know-how. We gladly provide
one-to-one advice – by telephone or on
your premises.
Development
We collaborate closely with our
users, and always to a system. New
developments are a perfect complement
to the product range, are modular,
expandable and versatile.
Production
Our carefully selected range of
high-quality raw materials and
components along with the latest
production equipment guarantee our
products are precision-made.
Testing
Tough tests during the production processes
ensure our high standards are met. Our
application technology department checks
your electrical connections and finds
solutions to your particular problems.
After Sales Service
We offer a worldwide comprehensive
technical service: from free-of-charge
tool hotline to maintenance and repair
service to equipment hire service.
Further testimony to the special Klauke quality – our certifications and awards:
ISO 16949
Management Systems
ISO 9001 ISO 14001
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Because modern cables are
smaller in diameter!
Our solution for compacted conductors.
New cables are up to 15 percent thinner than before.
Modern compacted conductors are much thinner than their comparable predecessors.
So nowadays, cable manufacturers can often save on sheathing and insulation. This
difference is not always obvious at fi rst glance. But it does mean that tubular cable lugs
and connectors that look as if they fi t have too much play and can no longer be crimped
as required. In the past, you have only been able to reliably avert this safety risk using
additional sleeves on compacted conductors.
Trend recognised – problem solved:
Klauke's new blue connection is a special connecting system for compacted conductors
to VDE 0295, Class 2. Comprising precision tubular cable lugs and connectors from copper
and custom-made crimping dies for Klauke's established tools, this development will enable
you to work and crimp simply, safely and effi ciently.
6

Conventional,
uncompacted conductors
- large cable diameter due to
conductor construction
- round single wires
Compacted conductors
to VDE 0295, Class 2
- Smaller cable diameters with the
same conductor cross-section
thanks to compacted single wires
Compacted conductors
with space-saving single wires
Uncompacted conductors
with round single wires
Comparison between conventional
cables and the new cable
generation with up to 15 %
smaller conductor diameter.
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Clever.
Klauke blue connection – the clever blue system.
Cable lug Crimping die Tool
Cable lug with blue crimp info + blue crimping die + blue crimping tool = blue connection
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We want to simplify each and every of your operations.
So we've made our new tubular cable lugs fi t perfectly on compacted conductors – without
the need for additional sleeves. The blue designation of the system elements ensures a simple,
logical application: blue to blue to blue. In practice, this means: the blue crimp markings
simplify work and everyone recognises straightaway that the blue connection connecting
materials and crimping dies go hand in hand.
9

Safe.
Klauke blue connection – safely connected.
Safety is paramount at Klauke.
Besides its improved designation system, our blue connection offers new blue crimp info –
enabling you to connect compacted conductors with certainty. This info tells you
exactly where, how often and in which direction you have to crimp. So you can reliably
prevent bad crimps and simply be safe: blue fi ts exactly. The extremely compact design
with characteristic form radius also ensures that the cable lug is especially stable and
safe under vibrations.
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Manufacturer's designation guarantees
original Klauke product quality.
Characteristic form radius
ensures stability and space
for washers
New designation system
240 = nominal cross-section
b = blue connection
12 = Ø connecting bolt
r = conductor class (UL conformity)
Optional inspection hole
in the cable lug for checking
the conductor's position
New blue crimp info shows the number
of crimps and crimping direction
Tested to IEC 61238, part 1
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Efficient.
Klauke blue connection – higher productivity at less effort.
Our mission is to enhance your performance and increase your cost efficiency.
Customers are already reaping multiple benefi ts from blue connection. With increased
productivity, the compact design has reduced material usage by up to 35 %. Given the
high price of copper, this creates a signifi cant price advantage.
But blue connection has other benefi ts too: Product selection, ordering procedures,
storage – everything is faster and easier, so your input is less. The new crimp geometries
with maximum crimp width reduce the number of crimps per cable lug, hence creating
distinct time and cost savings.
In short: effi cient.
12

Copper price development over the last 10 years
1.000 €
800 €
600 €
400 €
200 €
2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
Source: Westmetall, MK Listing
• In the last 10 years,
the price of copper has
almost quadrupled.
• With our new compact cable
lugs, we are minimising the
effect of the copper price.
Total costs per electrical connection
Costs
• Clear assignment thanks
to colour control system
and crimp info
• Effi cient stock-keeping thanks
to new packaging units
• Compact design cuts costs
• Sleeves no longer required
for compacted conductors
• Fewer crimps due to max.
crimp width
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Klauke blue connection –
the new cable lugs and connectors
Tubular cable lugs
Butt-connectors
Nominal crosssection
mm 2
Ø connecting
bolt
Part
No.
Nominal crosssection
mm 2
Ø connecting
bolt
Part
No.
Nominal crosssection
mm 2
Ø connecting
bolt
Part
No.
6 M5 6B5
35 M8 35B8
150 M10 150B10
M6
6B6
M10
35B10
M12
150B12
M8
6B8
M12
35B12
M16
150B16
M10 6B10
10 M5 10B5
M6
10B6
M8
10B8
M10 10B10
16 M6 16B6
M8
16B8
M10 16B10
M12 16B12
25 M6 25B6
M8
25B8
M10 25B10
M12 25B12
50 M8 50B8
M10 50B10
M12 50B12
70 M8 70B8
M10 70B10
M12 70B12
M16 70B16
95 M10 95B10
M12 95B12
M16 95B16
120 M10 120B10
M12 120B12
M16 120B16
M20 150B20
185 M10 185B10
M12 185B12
M16 185B16
M20 185B20
240 M12 240B12
M16 240B16
M20 240B20
300 M12 300B12
M16 300B16
M20 300B20
400 M16 400B16
M20 400B20
Nominal crosssection
mm 2
Part
No.
6 6B
10 10B
16 16B
25 25B
35 35B
50 50B
70 70B
95 95B
120 120B
150 150B
185 185B
240 240B
300 300B
400 400B
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Packing units
Part No. Standard POS
6B5 50
6B6 50 20
6B8 50 20
6B10 50
10B5 50
10B6 50 20
10B8 50 20
10B10 50
16B6 50 20
16B8 50 20
16B10 50
16B12 50
25B6 25
25B8 50 20
25B10 50 20
25B12 25
Part No. Standard POS
35B8 50 20
35B10 50 20
35B12 25
50B8 25 10
50B10 25 10
50B12 25
70B8 25
70B10 25 10
70B12 25 10
70B16 10
95B10 25 10
95B12 25 10
95B16 10
120B10 25 10
120B12 25 10
120B16 10
Part No. Standard POS
150B10 10
150B12 10
150B16 10
150B20 10
185B10 10
185B12 10
185B16 10
185B20 10
240B12 10
240B16 10
240B20 10
300B12 5
300B16 5
300B20 5
400B16 5
400B20 5
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Klauke blue connection –
the system
Connecting material
Tubular cable lugs
Angle tubular cable lugs
Angle tubular cable lugs
45° angle 90° angle
Butt-connectors
T-connectors
Cross-connectors
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Dies
Tools
16–400 mm 2
Series Crimping range Model
EK 35/4
6–150 mm 2 EK 50/5-L
6–240 mm 2 EK 60/22-L
6–300 mm 2 EK 120/42-L
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lue connection – Clever. Safe. Efficient.
Clever.
Safe.
> Simple application without sleeves
The new cable lugs perfectly match
for compacted conductors to VDE 0295, Class 2
> Clear and fast colour assignment
Connection materials with blue crimp info,
blue crimping dies and blue crimping tools
belong together
> Easy for all users to understand
> Simply continue to use existing tools
Only the crimping dies are replaced
> Reliable cable lug designation
Manufacturer's designation, nominal cross-section
and hole size are embossed
> Trend-setting blue crimp info
The number of crimps and the crimping direction
are clearly shown
> Compact design with form radius
Ensures increased stability and safety under vibrations
> Tested to IEC 61238, part 1
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Efficient.
> Faster searching and finding
The clear blue assignment and marking of system
elements enables you to work quickly and safely
> Lower storage costs
The new, smaller packaging units permit effi cient
stock keeping
> Lower material costs
The compact design reduces material usage by
up to 35 %
> One operation less
The time-consuming processing of sleeves for compacted
conductors is eliminated
> Fewer crimps thanks to maximum crimp width
> Best value-for-money
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Strong brands for your success:
Gustav Klauke GmbH
Auf dem Knapp 46
D-42855 Remscheid
Telefon: +49 (0) 2191 / 907 - 0
Telefax: +49 (0) 2191 / 907 - 141
E-mail: info@klauke.textron.com
Internet: www.klauke.com