Month: August 2022

DISCOVER TYPES OF LUGS AND THEIR USAGE.

 types of lugs

Electricians these days are making use of various Types of lugs on the electrical cables that provide a firm connection between the cable and the equipment. There are four types of cable lugs which are commonly used in electrical construction. Different types of cable lugs are also available based on their size. When a permanent connection is needed, then a cable lug or connector is used however a direct one is inconvenient or next to impossible to attain. Lugs comprise high-grade electrolytic (ETP Grade) and are available in a variety of diameters and mounting holes, with wire sizes that range from #8 AWG to 1000 MCM.

Types of cable lugs

Depending on the application and the industry, the usage of cable lugs differs. There are several alternatives for every installation framework. Types of lugs are categorized on the basis of their body structures, insulation and cross-sections.Copper lugs

Copper lugs are mostly used for power draw or grounding in large gauge applications. The wire can be mended or crimped to every copper lug. Subject to the specific type of lug used, one point of the copper lug takes the cable by welding, soldering or crimping. The other point of the copper lug is attached to a very end or connection point by a bolt, screw or spring clip.

Copper cable lugs provide simple installation and long-lasting authenticity. Pioneer copper lugs are made from high-grade copper material and tinned in order to protect them from corrosion. It is considered a brilliant option for any external application or in a marine environment.

Copper lugs are way better in several ways, however, copper lugs are a little more exorbitant compared to aluminium lugs. Flat-type lugs are largely used in the electrical industryAluminium lugs

Aluminium lugs are made from the solid aluminium rod using high conductivity (99.6 % pure) aluminium. The aluminium lugs are manufactured from solid and firm material and are apt for external usage due to the palm ends being sealed. The aluminium cable lugs are equipped with jointing compounds in the barrels and are sealed with a cap at the endpoint. Pioneer has a list of basic sizes but can produce aluminium lug types as per the needs.

Aluminium lugs are barrel entry chamfered at the end to allow for simple insertion into a barrel and are tinned with a middle layer of copper coating for corrosion protection.Mechanical lugs

The ideal approach for joining cable conductors is mechanical connection technology, which uses cutting-edge components like shear-off bolted connectors. At a preset torque, the bolt head is sheared off in this case. Certain alloys are used to make these mechanical connectors or shear bolt connectors. These connections consist of high-tensile aluminium alloy lug bodies and sleeves. The internal sides of the connectors are adapted and the sleeves are apt for underground use. These lugs are available in various palm hole sizes and are relevant both externally and internally. These products can be availed in low voltage, medium voltage and high voltage versions.Pin type lug

The connection part of pin-type lugs consists of a thin and elongated structure. It is found in the shape of a needle. It is designed to cut off conductors into contact blocks. It is used with respect to the termination of blocks and some electronic components. Pin type lugs are available in different sizes such as 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 120.

Types of lugs and their application

Lugs types and size also matter in order to ensure the efficiency and effectiveness of an electrical appliance.

One of the primary functions of copper lugs is the connection of wires to electrical devices. Both power cable systems and electronic equipment can benefit from the usage of copper lugs.

Copper lugs work well in both power cable systems and electrical equipment. Insulated lugs consisting of pin terminals, blade terminals, hook terminals, fork terminals and ring terminals are utilized in the wire, automation, control panel and instrumentation industries.

Butt and parallel connectors are other types of lugs that connect and cut off two cables. Among the most commonly used butt and parallel connections are PVC insulated, butt type, heat shrinkable and close-end type.

In solar plants, bimetallic lugs are used to join copper busbars and aluminium conductors in a variety of electrical applications, including combiner boxes, switchgear, and control panels. Whereas ring type of lugs is used in blot & nuts plotted areas. We use this type of connector in MCB, MCCB, ACB, OCB, and the electrical panel areas.

Boot-type connectors are frequently used for control and instrument cables. U type of lugs is used in the relays, timer, contactor and MCB areas. Understanding the types of lugs and their application is essential to choosing the right kind of lug for the required appliance.

Different types of cable lugs and sizes of electrical lugs

Ring type cable lug sizes: 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 120 (Diameter of the hole depends on bolt size such as 8 or 10)
Cable lug sizes of U type : 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 120
Boot lace type cable lug sizes: 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 120
Copper lug cable sizes range from: 1.5 sq mm to 1000 sq mm

Cable lugs sizes help to select the right kind of lug for a particular electrical appliance which helps in the efficient functioning of a particular system.

FAQs

What are cable lugs?

Cable lugs are connectors used to connect/cut off cables together constituting a significant part of an electrical system. Cable lugs are usually made up of one of two metals – copper or aluminium or their respective alloys.Why are cable lugs used?

Cable lugs help in the installation, restoration and maintenance of electrical gadgets and cables simple. They join two wires together or link more than two cables. They also connect load switches, fuse sockets and electrical equipment.Why are bimetallic cable lugs used?

Bimetallic Lugs are primarily handy where an aluminium cable has to be cut off by a copper bus bar or copper contact. The usage of bimetallic lugs assures a technically sound and lasting joint.What are cable lugs made of?

Cable lugs are usually made up of two metals – copper or aluminium or their respective alloys.How many types of lugs exist?

As per various installation processes and structural forms, lugs are divided into two types: bolt type and compression type.

HOW ARE COPPER LUGS INSTALLED?

Lugs form the most important part of an electrical system. Copper lugs are used for connecting/terminating wires and cable ends to electrical equipment. Its design allows it to easily secure and detach electrical joints permanently or for maintenance purposes. Since they connect devices seamlessly, they are essential for using electricity across different applications. Owing to its ubiquitous nature across devices, one must account for the quality of material used, correct type of lug, tools, and dies as they are crucial factors in determining the durability and reliability of the connection established.Classification Of Copper Lugs:

According to the structure, design, and types of connection established, the lugs can be distributed under two categories.Compression lugs-

The lugs are compressed along with the cable to establish a seamless connection. The joints between the wires and electrical equipment are crimped using relevant tools and dies which leads to lesser current loss.Mechanical lugs-

These lugs are designed to hold the bolts on one end and support the cable on the other. The bolts are then tightened for endpoint connection.

Cable Lug Design Specifics:

The two ends of the lugs are manufactured in a structure that supports cable and terminal connection on either end respectively. The cable is connected on one end using soldering, crimping, or welding. The use of any method depends on the connection to be established.

The other end is attached to the terminal point with a screw, bolt, or spring clip. The latter is selected on the basis of compatibility with the terminal type and method of connection.

Cable Lugs Installation Process- Things You Should Know

Step 1- Correct Identification

In accordance with four international standards, the cable lugs are available in different sizes and specifications. It follows:

  • Indian Standards
  • DIN Standards
  • BS Standards
  • AS/NZ Standards

Step 2- Preconditions

  • Any personnel involved must follow appropriate safety precautions.
  • The personnel must correctly identify the right type of lug for the required connection.
  • The crimping device must be of the recommended dimensions to create the perfect compression.
  • The insulation around the cable should be removed in accordance with the insertion depth of the connector and the wire strands should not be disturbed.
  • The surface should be brushed to remove any oxides.
  • Insert the cable strands into the barrel in its entirety and crimp it throughout.
  • Lugs should be used as per the recommended size and structure.
  • The cable insulation should not be stripped more than the recommended length to ensure an efficient and safe connection.
  • The crimping dies should be used as per the lug shape and structure.
  • The strands of the cable must be inserted into the barrel end of the lug. Once done, it should be made into a joint using crimping tools and die.
  • The barrel of the lug must be tightened around the uninsulated cable strands to maximize connection efficiency.
  • Every lug has a different crimping style and thus demands a different crimping tool. The proper crimping tool dies do not allow any loops for air space thus reducing resistance, increase in temperature, or fire risk.