tricab ALI-FLEX B21 User manual

B21
1. Select suitable size of ALI-FLEX®
Bi-Metallic Reducing Link by verifying that
the markings on the link and cables match.
Select the appropriate Copper Cable and mark
the stripping length as specified in Table 1:
Installation of Copper Conductor.
This Installation Guide was designed with great care and proper testing before publication to ensure the product works perfectly with TriCab
flexible cables. ALI-FLEX® Bi-Metallic Reducing Links are specifically designed, tested and certified for use with TriCab ALI-FLEX® cables
only. TriCab is not liable for any errors, omissions, damages etc. due to improper use of this product, included but not limited to improper
installation deviating from this Guide, safety and warning rules violation, using unsuitable cable other than TriCab flexible cable. TriCab
reserves the right to modify this Installation Guide at any time without prior notice.
www.tricab.com
2.
Carefully cut and strip the outer layers of the
cable (sheathing, insulation, fleece tape). Be
very careful not to nick or cut any strands of
the conductor.
Adjust the stripping tool so that
it cuts close to the conductor but leaves a
small amount of insulation to tear away by
hand. This will help protect the fine wires
during the stripping process.
Place the link at the end of the copper
conductor.
1
TCIM-ACC-B21 Rev. 07
ALI-FLEX® Bi-Metallic Reducing Link
Installation Guide
Striping Length of
Cable Insulation
5-10mm Clearance
3.
Gently push both the link and the remaining
section until they meet the jacket.
Cut and remove the section specified by the
dashed line.
4.
Carefully insert the copper conductor into the end
of the copper barrel making sure all strands are
contained within the barrel.
Do not twist the conductor.

This Installation Guide was designed with great care and proper testing before publication to ensure the product works perfectly with TriCab
flexible cables. ALI-FLEX® Bi-Metallic Reducing Links are specifically designed, tested and certified for use with TriCab ALI-FLEX® cables
only. TriCab is not liable for any errors, omissions, damages etc. due to improper use of this product, included but not limited to improper
installation deviating from this Guide, safety and warning rules violation, using unsuitable cable other than TriCab flexible cable. TriCab
reserves the right to modify this Installation Guide at any time without prior notice.
www.tricab.com
2
TCIM-ACC-B21 Rev. 07
B21 ALI-FLEX® Bi-Metallic Reducing Link
Installation Guide
5.
Select a suitable crimping tool with the correct crimp
force and note the required No. of crimps as speci-
fied on Table 1 (12, 25 or 60 Tonne). Choose the
appropriate Copper die by referring to the correct
A/F (across flats) die size on Table 1. The correct A/F
size is also printed on the copper barrel of each B21
lug. Please note that the mm² cable size markings
on AF dies from brands other than TriCab, have
no relationship to the mm² cable sizes for
CU-FLEX or ALI-FLEX cables.
Center of Barrel
Single Crimped Method
Min Gap
7mm
Two Crimped Method
6.
For hydraulic hex crimpers, place the lug on the
non-moving die and allow the other die to move up to
crimp. If more than 1 crimp is required (refer Table
1 for more details), begin crimping from the linked
end of the barrel and work towards the open end.
Position the lug to the correct crimp location on the
barrel as specified in Table 1. Do not crimp closer
than the minium gap specified in Table 1 from the link
end of the barrel.
Begin the crimping process and continue until the full
cycle is complete. Make sure the dies are fully closed
for sufficient crimping force. Release the ram and
repeat the process if more than 1 crimp is required.
Leave a 7mm gap between each crimp. Do not crimp
closer than 4mm from the open end of the barrel.
Refer Table 2 and repeat Steps 1-7 for the Aluminium
conductor
Check crimping result. Us a file if necessary to remove
burrs to have a smooth crimp surface. Apply suitable
ALI-FLEX® G03 Glue Lined Heatshrink over the entire
link to complete the crimping. Two layers of the
heatshrink should be applied if the link is outside an
enclosure. The heatshrink should cover both barrels and
approximately 50mm of the cable jacket on either end.
Min 4mm
7mm
8.
9.
Min Gap
7.
Min 4mm

(*) In case of using dies with different length of crimp face from specified above, the total effective crimp length
(crimp length x no. of crimp) should be equivalent or greater to maintain a secured mechanical and electrical
connection.
This Installation Guide was designed with great care and proper testing before publication to ensure the product works perfectly with TriCab
flexible cables. ALI-FLEX® Bi-Metallic Reducing Links are specifically designed, tested and certified for use with TriCab ALI-FLEX® cables
only. TriCab is not liable for any errors, omissions, damages etc. due to improper use of this product, included but not limited to improper
installation deviating from this Guide, safety and warning rules violation, using unsuitable cable other than TriCab flexible cable. TriCab
reserves the right to modify this Installation Guide at any time without prior notice.
www.tricab.com
3
TCIM-ACC-B21 Rev. 07
Table 1. Installation of Copper Conductor
B21 ALI-FLEX® Bi-Metallic Reducing Link
Installation Guide
Table 2. Installation of Aluminium Conductor
Conductor
Size Die A/F
mm² mm 12-13 tonne 25 tonne 60 tonne mm mm
16 9.0 1 Crimp x 22.0mm 32
25 9.0 1 Crimp x 22.0mm 32
35 13.2 1 Crimp x 22.0mm 32
50 17.3 2 Crimps x 22.0mm 60
70 17.3 2 Crimps x 22.0mm 60
95 17.3 2 Crimps x 22.0mm 60
120 22.0 2 Crimps x 18.0mm 60
150 22.0 2 Crimps x 18.0mm 60
185 28.4 2 Crimps x 18.0mm 60
240 28.4 2 Crimps x 18.0mm 60
300 39.0 1 Crimp x 50.0mm 13 70
400 39.0 2 Crimps x 25.0mm 1 Crimp x 50.0mm 10(25T)/13(60T) 70
500 43.2 1 Crimp x 50.0mm 70
630 43.2 1 Crimp x 50.0mm 70
Stripping Length
of Cable Insulation
Use Adaptor and
Standard 12 Tonne
Dies
Hydraulic Tools - Hexagonal Die
No. of Crimp x Crimp Face Length*
B21 AL SELECTION TABLE - ALI-FLEX BI-METTALIC REDUCING LINK Crimp Distance
from Barrel Front
Edge
Use Adaptor and
Standard 12 Tonne
Dies
13
10
Conductor
Size Die A/F
12-13 tonne 25 tonne 60 tonne
mm
10 5.7 1 Crimp x 6.4.0mm 10 10
16 6.3 1 Crimp x 17.5mm 19
25 7.7 1 Crimp x 17.5mm 21
35 9.2 1 Crimp x 17.5mm 21
50 (AL-70) 10.4 1 Crimp x 17.5mm 22
50 10.4 1 Crimp x 17.5mm 40
70 11.5 1 Crimp x 17.5mm 40
95 14.2 1 Crimp x 17.5mm 40
120 16.5 2 Crimps x 14.0mm 40
150 18.3 2 Crimps x 14.0mm 1 Crimp x 16.0mm 15 40
185 20.0 2 Crimps x 14.0mm 1 Crimp x 16.0mm 15 55
240 23.1 3 Crimps x 10.0mm 1 Crimp x 16.0mm 55
300 26.0 3 Crimps x 10.0mm 1 Crimp x 16.0mm 1 Crimp x 25.0mm 55
400 28.1 1 Crimp x 16.0mm 1 Crimp x 25.0mm 55
500 31.0 1 Crimp x 16.0mm 1 Crimp x 25.0mm 55
Stripping Length
of Cable Insulation
Hydraulic Tools - Hexagonal Die
No. of Crimp x Crimp Face Length*
B21 CU SELECTION TABLE - ALI-FLEX BI-METTALIC REDUCING LINK
4
mm² mm 12-13 tonne 25 tonne 60 tonne
Crimp Distance from Barrel Front Edge
mm
Use Adaptor and
Standard 12 Tonne
Dies
Use Adaptor and
Standard 12 Tonne
Dies
6
13
5
10
24
20