Copper Crimp

hellermantoolThe hand compression-jointing tool has been designed to enable D10 or Lightweight Quad to be joined quickly and efficiently, in a permanent joint, using the appropriate Hellerman splicing sleeves. The joint does not require insulating by tape after completion, as the sleeves are self-insulating. When done correctly, the joint is stronger than the actual cable and is reasonably waterproof.

The splicing sleeves consist of an internal copper core, insulated from an external copper sheath by clear polyethylene sleeve.

The jointing tool is operated by hand compression and incorporates a ratchet which prevents the opening of the handles and the release until full closure of the crimping jaws is achieved.

Hellerman JointA combined stripper and cutter, with a fixed abutment, is located on the back of the tool. When the end of the wire to be stripped is placed across the stripping blade and is held firmly against the abutment whilst the stripping operation is completed, it ensures that the correct length of wire is bared for insertion in the sleeve. Or you can also use a pair of snips to do the same job.

Jointing Lightweight Quad:

Note: The procedure for jointing D10 cable differs slightly from the procedure for jointing lightweight quad cable. When D10 cable is being jointed, both cores must be cut, twisted and jointed, staggering the joints to prevent bulkiness which may impede the free passage of the cable through pay-out equipment. When lightweight quad cable is being jointed, all 4 cores must be cut and jointed, staggering each pair to prevent bulkiness. Great care must be taken to ensure that all 4 jointed cores equally share the mechanical strength of the cable.

Preparing the Cables

Strip away the outer PVC sheath of the cable for a length of 80mm, taking care to keep the length the same on each end.

Hellerman JointStrip back the inner polyethylene insulation of each cable for a length of 70mm, leaving 10mm exposed before the outer PVC sheath.

Hellerman JointSelect one black core and one white core in each cable and cut off 35mm of their exposed length, as below.
Note: As the mechanical strength of the final joint must be shared equally between the joints of the 4 cores, it is essential that the shortened lengths are the same in each cable.

Hellerman JointFollowing the instructions given, strip 8mm of the end of each core in preparation for jointing, ensuring that the correct length is stripped from each core.

Hellerman Joint

Making the Joint

Select a long black core and a short black core of the other cable end, taking care not to spread the conductors. Marry the 2 ends in the splicing sleeve (Copper Crimp) and then crimp the two ends together using the Hellerman Crimping Tool. The success of the joint depends on the efficient inter-weaving of the 2 ends in the copper crimp and the operation must be performed with care. Otherwise you end up with 1 side of your cable coming back out of the copper crimp even though it has been crimped.

Hellerman JointJoint the second pair of black cores following the instructions given above. Repeat the operations with the white cores, so your cable joint should now look like this.

Hellerman JointWith all joints made as described above, stretch the jointed cable tightly between your hands and note whether all cores are securely in correctly.

A joint should only be wrapped with insulation tape if it is going to be used as a permanent installation. If a cable is being constantly laid and recovered for exercise purposes you would need to regularly check that the joints are still holding so there would be no point.