Cable Lugs: The complete Buying Guide

as a lugs manufacturers, DIFVAN-all kinds of copper tubular lug manufacturer and expert, we will write everything about cable lugs in this article we will learn something about the cable lugs together, this articles will help you to have a clear understanding of the types specifications of cable lugs. in our company, we devided the cable lugs into three big type per the material difference:Copper Cable Lug, Aluminum Lugs, and Bimetallic Lugs for your cable assembly.

According to our customers’ applications, these three types of lugs all have a super function for connecting wires.

here is the scripts of the whole parts:

What is a Cable Lug?

As part of the modern-day wiring and electrical industry, electrical connectors have been one of the major devices that can be temporarily or permanently be used in connecting or terminating any electrical circuits.

Due to demands and needs, electrical connector is one of these types of electrical connectors created. You can use it for connecting electrical and mechanical equipment.

It is designed in a way that you can easily connect or terminate a cable to an electrical device or equipment cable assembly like:

1. power cables
2. electrical boxes
3. Automobiles
4. household appliances.

Cable lugs are invented for a safe connection to both the user and the equipment being connected. You can also be certain that no matter what type of cable lug it is, it’ll be easy to use and connect.

One of the things you should know is the different ways a connection could be secured. It could be by bolt, screw, or stud.

This is to help you identify what specific types of a copper tubular lug you need in connecting your equipment. Cable lugs are also commonly designed from three types of metal.

They are Aluminum and Copper.

1. Aluminum cable lug
2. Copper Cable Lug
3. Bimetallic cable lug

BUT what is the difference between the three?

Type of Cable Lugs?

Due to demands and needs, copper compression Lug terminal connector is one of these types of electrical connectors created. we devided the cable lugs into three types per the material of the lugs used. they are: Copper lugs, Aluminum Lugs, and Bimetal lugs. when you have the wire in your hand, which lugs will be your need and how to choose your right lugs. 

Copper lugs, Aluminum Lugs, and Bimetal lugs, which one should you choose?

COPPER LUGS

Copper cable lugs, are made from 100% electrolytic copper tube and crimping by punching machines from copper tube. Good punching machine and perfect mold can make the lug to have no burr appearance.

Then crack free splice from annealing process to make the cable lugs more strong.Tin-plated surface prevents oxidation and ensures maximum corrosion protection.

Apart from the 180-degree type, another 45⁰, 60⁰, 90⁰ and 120⁰ are also available to match different applications.

being a cable lug supplier, DIFVAN copper compression lug is an ideal lug for power grounding supply in large gauge applications. On the end of each battery cable lugs, they can be crimped, welded or soldered to a wire using a bolt, screw or spring clip.

The size can vary from 1.5 Sqmm to 1000 Sqmm, with varying bolt sizes. One hole and two holes are both available. They are widely used to terminate cables to distribution boxes and transformer.

This copper cable lug terminal connector is the best connecting lug for wires. Conductivity rate is more than 97%. For most stable performance, a higher coefficient indicates a greater risk of fire.

ALUMINUM LUGS

The aluminum lug is made using 100% aluminum. It is was one of the first wire connection that was used back in the 1960s.

This was just after the innovation and during that time, aluminum was one of the first metals to be used.

During that time, aluminum wire was used nearly in every house, explaining why aluminum lug was common.

As time passed by, the electric experts faced many failures when using aluminum lugs. There was frequent fire outbreak due to electrical faults.

After research, it was established that aluminum lugs were the main cause of this problem. It was because aluminum oxide formatted when in use.

After that, electric experts opted for copper lugs.

It is true that in the early days, aluminum simply wasn’t the right choice for lugs, and since then, copper became the preferred choice for lugs. All things considered, however, it’s now much safer to use aluminum lugs as compared to the earlier days.

Despite these improvements in aluminum wiring and electrical components, somehow the impression that copper lugs are better than aluminum hasn’t really gone away.

This way, the bimetal lugs were introduced.

If copper or aluminum cable lugs are used, a galvanic action occurs due to dissimilar contact.

The use of bimetallic lugs thus ensures a technically sound and durable joint.

BIMETALLIC LUGS

DIFVAN bimetallic lugs are composed of two unique materials: the barrel of the electrical cable lugs is made with a 60% conductivity rate aluminum alloy and palm of the lug is made of 60% conductivity rate forged copper.

These two parts are joined together through a friction stir welding process. The barrel is filled with neutral grease to prevent oxidization and improve connectivity. The final product is fully annealed to ensure strong mechanical performance.

Advantage of bimetallic lugs:

• Safe to use and cost effective
• All copper products are electro-tinned to BS standard and prevent them from corrosion and oxidation.
• PVC insulation is provided to terminals for exceptional di-electric strength & for support
• Entry to the wire barrel is shock-proof, or bell-mouthed for faster and easier conductor entry.

Difference between the three Cable Lugs

what is the difference between Copper Lug, Aluminum lugs and Bimetallic lugs?

Aluminum is a cheaper type of metal while copper costs a bit higher.

Other than that, in the early days of the electrical industry- unprotected aluminum types of lugs have caused quite a few problems like aluminum oxide formation and its low thermal expansion properties causing many electrical devices for failure.

An electrical equipment market from different countries now requires an all-copper installation; because copper has been proven to be safer in using in any electrical devices.

That is why different electricians created the recommendations that aluminum lugs should be used with aluminum conductors and copper.

You could also use aluminum lugs to terminate copper conductors because of the following factors:

1. More Safer
2. More Cheaper

But because of the modernization of the electrical and mechanical industry, aluminum lugs are now also as safe and secure as that of copper compression lugs.

You don’t have to worry about connection failure and at the same, still, have the have option of buying one at a lower price.

Types of Lugs

If you are having a hard time choosing what type of cable lugs to use, we listed the following types of cable lugs based on their features: installation process and safety features.

1. Copper Terminal Lugs

A Copper Terminal Lug is a type of a copper compression lugs that is used in fastening connections to a terminal. they can be found from many copper lugs manufacturers around the world.

It is designed to connect in different ways like a stud, a chassis, or to one end of a terminal. It may also be connected in various ways like screwing, pressing or crimping.

This type of cable lug from a professional copper lugs manufacturer is also used for attaching wires or electrical conductors copper conductor for an electrical connection that may need a tool or device for the wire to connect to the electrical cable lugs. you can contact our tems to get more information of manufacturing process.

2. Aluminum Tubular Lugs

raw material of An aluminum tubular lug has a tin-plated surface.

This is used to terminate sector wires or aluminium round so that you’ll have a reliable connection between ends of aluminium lug conductors in enabling easy installation.

3. Bimetallic lugs

DIFVAN as a electrical lugs manufacturer, our Bimetallic Lug is a type of lug that uses both types of metals joined together (but not as a mixture) and consists of layers of these two types of metals.

This is mostly used in termination of aluminum cable using a copper bus bar or copper contact copper conductor to avoid a galvanic corrosion (bimetallic corrosion) because of dissimilar contact.

4. Mechanical Lugs

A Mechanical Lug is used in connecting big cables and is commonly used in an automobile.

They vary in sizes and may also cater 2 or more conductor’s barrels.

They are also called heavy-duty lugs because mechanical connector are designed with high-grade electrolyte copper or aluminum that can hold severe vibrations.

The plain type is generally used in all types of connectors. The sight hole is designed with a bigger hole to cater more cable sizes and as a connector type.

mechanical connector may be flared or chamfered type of barrels depending on the need of an electrical device.

Functions and Uses of cable lugs

What are the functions and uses of cable lugs?

compression cable lug are designed in various sizes and purposes.

The tongue or the connecting end of a lug vary in terms of ranges of wires it can accommodate for connection purpose.

An example is a terminal connection where a fork or u-shaped lug is used for screw terminal. Closed ring or the O-type is used for bolt-on connection; while the pin or spade lugs are used for pin or blade terminals.

You may note that it is also available in copper or aluminum for different purpose of connection and compatibility with the connecting device. different lugs manufacturers have their different standard and their molds for stranded wire.

DIFVAN CABLE LUG also designed with an insulation support and stranded wire insulation which aims in reducing corrosion with the wirings or short circuits cross section that might affect an electrical device that could harm the user. we can shared you manufacturing process to see our high quality product.

Now, we listed the following uses and functions of compression cable lug to give you a better idea of how and what it is used for:

Cable Connector or Terminator

You may find The main purpose of aelectrical lug is to connect or terminate a cable wire and a terminal or power output/input of electrical and mechanical equipment.

This is to allow you to have a better connection between an electrical current passing through the cable and the lug to its target point for a stranded wire.

It is also an easy way of installing cable connections cross section which is the same in terms of removal for repairs and maintenance.

Cable Size Reducer

One of the main functions of a mechanical connector is to reduce the size of the cable wires before connecting to the power output/input or any electrical terminals for a stranded wire.

There are instances wherein your electrical equipment, from an automobile to a simple household appliance needs a bigger cable to connect to a specific connection.

mechanical connector is designed that can hold a different type of wires so that your electrical connection will be easier.

This allows you to connect thick cables to a connector with a smaller diameter you possibly have.

Safer Connection

wire lugs was invented so that it ensures the electrician and the users’ safety.

When making connecting wires before, it is commonly connected directly to the power source or terminal through the use of a soldering iron or an electrical tape and the like.

It is considered an unsafe way of connecting any wiring to another for electrical product.

There is also a high probability that the connection won’t be durable in the long run and might come loose due to vibrations and other possible reasons.

A wire lugs is a flexible tool.

If your cables need to be removed or replaced multiple times, this helps you become worry-less that it may damage the copper wires of a cable, or causing malfunctions and short circuits with the equipment (especially direct wire connections).

Cable Wire Holder

A wire lugs is connected to a cable wire through crimping for a electrical product.

It means that the barrel of the lug is deformed with the use of a crimping tool securing all the copper wires inside the lug’s barrel.

This helps you to hold the cable wires securely and tightly than when it is directly connected to a terminal or power input/output connection.

It both serves as a holder of the cable wire and the connector for an electrical current to pass through with ease.

Which Tools can be used for Cable lugs?

A Crimping Tool is commonly used in cable lugs as a device to join the lug and the cable by crimping the barrel end of the lug to help hold each other’s connection.

DIFVAN Crimping a lug makes it deformed at its barrel end by pressing the cable wire between the lug’s barrel gripping it and securing the cable wire inside and lug’s barrel.

The same with electrical cable lug, a cable crimping tool or any crimping tool also vary in sizes according to the size of the cable and the lug you need to use.

The bigger the cables and lugs, the bigger the crimping tool should also be used. except electrical cable lug, aluminium lug in aluminium material, some lugs manufacturers also provide electrical product in stainless steel material for connecting terminal.

 Crimping Tool (size: YQK-70, YQK- 120, YQK-240, and YQK- 300)

A large crimping tool can even accommodate cable and lugs from 6mm² up to 1000 mm².

Smaller crimping tools have their limitations depending on the range capacities of each crimping tool can cater.

Some also require one crimp while others need to have a series of three (3) crimps to have the correct compassion (Cold Weld) between the cable wire electrical lug and the cable lug.

It is important that you also know how many times does your electrical lug needs to crimped.

This is an important process that helps avoid overheating on your devices and possible failure.

The most commonly used tools are in DIFVAN are :

1. YQK-70: Suitable for cable lug size range 4-70MM²
2. YQK-120: Suitable for cable lug size range 10-120MM²
3. YQK-240: Suitable for cable lug size range 10-240MM²
4. YQK-300: Suitable for cable lug size range 10-300MM²

Important Notes to Consider in Using a Crimping Tool

There are various pointers that should be considered when using a crimping tool. If you overlooked on this matter, it can cause joint failures or short circuits.

1. Know the Size

You have to consider the size of your cable and cable lug when using a crimping tool. Each crimping tool has ranges of cable lugs that it can accommodate.

The bigger the cable lug, the bigger the range of the crimping tool must be used. This should be considered so that connection failures may be avoided.

You must make sure the cable wire is correctly crimped in a cable lug. All the air voids are removed to make it look like a whole material.

Every single strand of the copper wire friction welding was compressed to a proper hexagonal shape that helps avoid connection failure.

The correct crimp should have a crisp edge.

Improper use of the tool can result in over crimping (winging or flashing) and loose crimping.

When you use a die or crimping tool that was too small for its size, you can press the copper wires too much and beyond what your cable lugs need.

If you use a big crimping tool, the cable lug makes it look like you barely crimped the copper terminals.

Both ways are dangerous and might cause overheating and termination failure.

You may cause fires in your equipment if you won’t do it right.

Another way to know is by just simply looking at the crimped edges.

If it is crimped too deeply then, it’s possible that the crimping tool used was incorrect or too much pressure was used.

If it’s barely visible, the crimping tool is either too big for the copper terminals or crimped too loose.

In this video, you can see two methods which were used to crimp ring terminals onto a heavy gauge table:

2. Use Vernier Caliper

You can’t just simply cut your cable lug just to check if it is crimped correctly.

There is another way to check if you think your cable lugs are crimped well by using the Vernier Caliper tool.

It is used by measuring across the hexagonal flats of the crimps which are called the AF.

You may check any Cable Lug Catalogs to know the correct AF sizes for a specific size of a cable lug specification you have.

Copper and Aluminum are different so check whether it is made of aluminum and Copper should also be considered in checking AF catalog.

Cable Lug Standard

What are the Standard Sizes of Cable Lugs?

There are different standards sizes for cable lugs that you need to know for the availability of the product and the recommendations of a certain country in using a specific type of cable lug specification for your electrical equipment.

These are the following standards:

Indian Standards

The Indian Standards for sizes of Cable lugs varies from each type of cable lugs.

Though mostly, their cable lugs are only available in Aluminum as per IS 8309.

For example, their Aluminum Tubular Terminal End they can accommodate Stud sizes from 3.2 E up to 20.3 E.

While in terms of cable wires sizes, it can accommodate from 50mm² up to 1000 mm².

DIN Standards

DIN Standard also is known as Deutsches Institut für Normung e.V. is a German Institute for Standardization that provides companies a basis for the quality and safety standards that aims to have an assurance in quality products, environmental hazard-free production.

The DIN Standards as per DIN 46235 have wide ranges of available sizes that each corresponds to each type of cable lugs.

Each size also varies of in cables that they could accommodate.

For example, is their Tubular Compression Cable Lugs that is commonly used in control panels, switch gears, circuit breakers and transforms have a Stud Hole size that can range from 5.3 E up to 21 E.

While the cable size in mm² can accommodate 6 mm² up to 1000 mm².

While their Compression Cable Lugs according to DIN 46235 cable wire sizes from 6mm² up to 1000 mm².

BS Standards

The BS Standard also is known as the British Standards in standard sizes of cable lugs. Their standards differ depending on the type of cable lug, it may be uninsulated as per BS 7609 and pre-insulated as per BS 7727.

Their pre-insulated compression terminal and connectors for copper conductors can accommodate from 6mm² (BS 7609). In un-insulated compression terminal and connectors for copper conductors can accommodate from 10 mm² and above, while in terms of aluminum conductors it can accommodate from 16mm² and above.

AS/NZ Standards

The Australian Standard also has their standard sizes that range from each type of cable lug.

Their standardized cable lugs are widely used in Electrical industries that ensure the qualities and strength of their lugs.

For example, their Cable Terminal ends have a Stud Hole size that ranges from copper strips 4.2 E up to 18.4 E, while in terms of cable size they can accommodate from 1.5-4 mm² up to 630 Bl mm².

NOTE: An important detail that you have to consider in buying and using a specific type of a cable lug based on their different standards is to make sure that you check their available Cable Lug Catalogs so that you’ll know the necessary information, from wire size compatibility; uses and its functions; crimping process and others

The 3 Groups of Cable Lugs for Copper Connectors:

The following cable lugs are the three most common cable lugs for copper conductors.

This will help you in selecting the correct cable lug for copper connectors.

1. Compression cable lugs to DIN 46235

A Compression Lug is manufactured from raw material electrolytic copper and tin-plated that protects it from corrosion.

It also has a marking which provides information on width and number of crimps to be used, making it easier to know where and how to use it.

It is also typically made out of high conductivity wrought copper that is generally used for telecommunications equipment and utilities, transformers, welding equipment, generators, and other power distribution equipment.

It has a short barrel type of lug that is usually used for switch gears or motor controls.

Compression cable lugs are also preferred to be used in smaller scale connections like home or small commercial buildings wire connections.

Good thing, it is easier to find the correct size which makes your connection job easier.

Compression Cable Lugs DIN 46235

2. Tubular cable lugs as commercially-available standard versions

A Tubular Cable Lug is one of the standard versions of a cable lug.

They are commonly used and are shorter in dimensions and length. Typically, all various profiles of crimping are not possible in a cable lug.

However, this is an exemption in terms of the tubular cable lug because multi-stranded conductors, sector-shaped, and fined- stranded conductors can be processed in this cable lugs without having any negative impact.

Unlike the DIN compression cable lugs that can only be used through a specific cable wire compatibility and crimping profiles, Tubular Cable lugs cost less because it requires less copper and the tubular cable lugs wall thickness is thicker than that if a DIN cable lug.

Tubular Cable Lug

3. Solderless terminals to DIN 46234

A Solderless terminal is a type of terminal lugs that does not require a solder to have an electrical connection.

It may also be insulated or non-insulated.

It is used for crimping, multi, fine, or superfine stranded conductors that copper strips range from 0.5 mm² to 240 mm².

A solderless terminal to Din 46234 is however not suitable for a single-stranded solid conductor.

They are commonly used for control cabinet construction or in constructing rail vehicles.

It is made from electrolytic copper and manufactures from copper sheets.

Commonly, a copper end sealing ferrule is hexagonal in size when crimped but a solderless terminal is by indent crimping.

Solderless Terminal DIN 46234

Here’s a helpful video on how to know when to crimp vs. solder:

In summary, cable lugs have great and beneficial uses to all electrical devices from the installation, up to repair and its maintenance.

It is very useful when connecting one or two cables together to make a seamless and safe connection.

Aside from cable connections or power lines, a copper end sealing ferrule is used to connect fuse sockets, electrical appliances or switches.

For safety purposes, the connectors that are widely available are made up of rubber or plastic insulated sheets.

Cable lugs come in a variety of sizes, shapes, and material depending on their specific uses.

The strength and shape are important in every industry it is to be used for.

For example, connectors that are used in the power distribution energy with high voltage power have a thick layer of insulation.

The one commonly used for all industries use butt and parallel connector for safely connecting equipment.

In terms of picking which is better between aluminum and copper lugs, please bear in mind that both have good advantages depending on its functions.

These two metals are very important in every home electrical system.

Aluminum lugs have been used in the past for all electrical purposes due to its performance and affordable, yet practical and effective usage.

Copper lugs are even safer because they help in doing away with fire hazards and have now been popular and used in any country around the world. we also have other accessory like cable tie. heat shrink tube, tools, and other fittings for your choosing.

Need more help and information about cable lugs? need more help for choosing the specifications of the terminal connector which will be work in your junction boxes? need to make the terminal connector to your cable assembly? need a leading manufacturer of electrical cable lugs to provide you help during your importing of the product? Here you’re in the right place.

You can send as an email and we’ll be glad to assist you with any of your concerns!