As global demand for renewable energy continues to rise, wind farms are becoming larger, more powerful, and increasingly complex. A single modern wind farm can contain dozens of turbines, each requiring dozens of medium- and low-voltage cable connections from the generator in the nacelle down through the tower to the collection network.
Every one of those connections must carry full load current, survive decades of vibration and weather exposure, and be installed correctly the first time — because reworking a connection inside a tower is expensive, difficult and dangerous. Reliable electrical connections are critical to ensure stable power transmission inside wind turbine systems.
Among the many connection technologies available today, shear-head bolt terminals have become a preferred solution for medium- and low-voltage cable installations in modern wind farms, and for good reason: they replace the heavy, skill-dependent crimping process with a simple mechanical tightening operation that produces the same consistent result every time.
MV Mechanical Shear-head bolt terminals connectors are mechanical cable connectors equipped with specially designed bolts that automatically break off when the required tightening torque is reached. This guarantees proper contact pressure between the conductor and terminal without requiring installers to use calibrated torque tools.
The principle is elegantly simple: each bolt is factory-calibrated to a preset torque value, and the bolt head is machined with a reduced cross-section at its shear point. As the installer turns the bolt with a standard hex key, the head twists off automatically the moment the correct torque is reached. The shear-off event is the installer's unambiguous signal that the connection is complete and correctly tightened — no torque wrench, no pressure gauge, no die set and no operator judgment are involved.
This design eliminates the two most common failure modes of traditional compression connections. First, it removes dependence on the operator: the connection quality no longer varies with the installer's skill, experience or physical strength. Second, it removes dependence on tooling: there is no hydraulic pump to service, no die to select for each conductor size, and no power supply required at the worksite. The result is a connection method that is fast, repeatable and verifiable, which is exactly what wind farm construction needs.
These terminals are commonly used for:
1) Wind turbine power connections — carrying generator output current reliably in the nacelle and down the tower
2) Medium voltage cable systems — connecting MV cables up to 36 kV in collection networks and feeder circuits
3) Transformer connections — terminating cables at transformer bushings where connection quality is safety-critical
4) Switchgear installations —providing secure, maintenance-friendly connections inside MV switchgear panels
5) Renewable energy distribution networks — serving wind farms, solar plants and hybrid renewable projects
They are suitable for both aluminum and copper conductors, making them highly versatile for wind energy projects. Jera Line's MV mechanical cable connectors are manufactured from tin-covered aluminum material, which creates a stable interface with both conductor metals: the tin plating prevents galvanic corrosion at bimetallic joints, while the high-conductivity aluminum body keeps weight low and current-carrying capacity high. Because one connector family handles both copper and aluminum cables, contractors can standardize their stock and avoid the risk of using the wrong connector type on site.
Wind farm installations are often performed in difficult environments such as offshore platforms, mountain regions, remote deserts, and cold or humid climates. Technicians frequently work at heights inside turbine towers where space is limited and weather conditions can change rapidly. In these environments, installation safety becomes extremely important.
Consider what a typical installation actually involves. The technician climbs into a confined space inside the tower, often wearing gloves and working in awkward positions, with the cable hanging and moving slightly under its own weight. Any tool that must be hauled up the tower — a hydraulic crimping head, a pump, a set of dies — adds physical burden and creates additional risk of dropped objects. Any procedure that requires careful torque measurement adds cognitive load and the risk of error. And any mistake that is not caught immediately can become a hot joint that fails years later, forcing an expensive outage and a repeat visit to the same tower.
Jera Line's MV Mechanical clamping cable connector portfolio provides a reliable solution to these challenges. With shear-head bolt technology, each installation is automatically controlled to achieve the correct tightening torque, significantly reducing the risk of human error. This ensures consistent electrical performance even when installations are carried out by different technicians or in difficult field conditions. Because the connector is installed with a simple hex key, technicians carry minimal tooling up the tower, spend less time at height, and finish each connection with the mechanical confidence that the shear-head break provides. The safety benefit is threefold: fewer tools at height means fewer dropped-object risks, faster installation means less exposure time in confined spaces, and guaranteed correct torque means fewer latent faults that could cause future failures.
The MV mechanical cable connector series covers cable sizes from 16 to 1000 mm², spanning the full range of conductor cross-sections used in wind power projects, from turbine auxiliary circuits to large collector cables. The series includes proven models such as the CCBI-10-4-25-50, CCBI-10-4-70-120, CCBI-10-4-150-240, CCB-I-20-4-70-120, CCB-I-20-4-150-240, CCBVzT-36-4.S(H)-70-240, CCBVzT-36-6-185-400 and CCBVzT-36-6-400-630, covering both 10 kV/20 kV distribution systems and 36 kV medium-voltage systems. The number of shear-head bolts scales with the conductor size — from four bolts on smaller models up to six or more on large-section connectors — ensuring that contact pressure is always distributed evenly across the full clamping length.
MV Mechanical shearbolt cable connectors（16-1000 mm² ）
By combining easy installation, high mechanical strength and dependable electrical performance, Jera Line's shear-head bolt terminals help wind farm operators improve installation efficiency, reduce maintenance requirements and ensure stable power transmission throughout the service life of the project.
The factory-calibrated shear-head torque removes the need for heavy crimping equipment at height, the tin-covered aluminum alloy construction guarantees stable contact with both copper and aluminum conductors, and IEC 61238-1-3:2018 third-party type testing with batch-by-batch laboratory verification provides the long-term reliability that wind energy projects demand. Whether the application is turbine power connections, transformer terminations, switchgear or grounding systems, the series offers a complete, verified solution from 16 to 1000 mm².
The speed advantage is equally clear: a shear-head connection is completed in minutes with a single hex key, compared with the time required to set up, operate and dismantle hydraulic crimping equipment — directly shortening turbine commissioning schedules and reducing the exposure window for crews working at height.
For more information, please feel free to contact us — we're here to provide professional solutions! We supply complete technical datasheets, free pre-order product samples and formal project quotations to support your wind farm procurement and field verification.
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