How to choose Copper Cable Lugs?

On the market, hundreds of different kinds of cable lugs are available. For the electrician, it is very difficult to choose from this broad range the correct cable lug for each specific application. The following article gives an overview of the different types of cable lugs for copper conductors and details the facts which will guarantee a safe and long-lasting connection.

At first, we differentiate between two types of cable lugs

DIN46235 Copper Compression Cable Lugs   Copper Compression Cable Lugs C Type

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Compression cable lugs according to DIN 46235

DIN standard 46235 defines the application, dimensions and marking of cable lugs. This standard allows use of these cable lugs for compression of solid, stranded, fine stranded and finest stranded copper conductors. The Utilities market for instance offer a wide range of applications.

For installing, the DIN standard recommends crimping dies according to DIN 48083, part1, 3 and 4 for solid, stranded and fine stranded conductors. For braided ropes the standard refers to the information of the manufacturer.

KINGO generally recommends the use of hexagon crimping dies according to DIN 48083, part 4 for installing of compression cable lugs DIN 46235. Range of cross section is from 6 mm² up to 1000 mm², bolt sizes range from 5 mm up to 20 mm. Electrolytic copper according to EN 13600 is mandatory. For corrosion protection, compression cable lugs – also tubular cable lugs and terminals – are tin plated.

Copper tube cable lugs

Apart from DIN cable lugs, many manufacturers also offer tubular cable lugs. As far as sizes are concerned, tubular cable lugs are mostly shorter than DIN cable lugs and also differ in tube dimensions (Picture 3, 4). However, since these lugs are also subject to test standard IEC 1238 part 1, durability of electrical and mechanical connection is not affected.

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All cable lugs – irrespective of type – can only be crimped properly when a suitable tool is used. Incorrect tools or an unprofessional crimp can result in increased joint resistance, increased temperatures and even fire. (Picture 5). To exclude such consequences, KINGO recommends for crimping of their cable lugs the exclusive use of their appropriate crimping tools.

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