How to Properly Install Copper Cable Lugs for a Secure Connection

Copper cable lug: Installing copper cable lugs might appear something straightforward, although improper installation can cause grievous effects such as loose connection, overheating, and even the advent of electrical fires. When making connection in a control panel, power cables, or any inverter connection, it is very important to know how to make the connections safely; as well as to make a safe and efficient system. ? 1. Chose the Right Lug A copper cable cross sectional area (sq mm) equals the copper cable lug before it is installed. Inappropriate size can cause ineffective crimping and hence loss of conductivity and development of resistance at the joining end. Hint: Whenever possible, consult a lug size diagram or specific manufacturers guide to be compatible. ? 2. You have to prepare the Cable Properly With help of a wire stripper, strip the cable insulation, but do not damage the copper strands. Strip out only that which will suit the length of the barrel of the lug-- no longer, no shorter. In case you do not twist or thin out the ends of the cables once it is stripped. ? 3. Slide Cable all the Way into Lug Insert the stripped cable end far into the barrel of copper plug. The cable must connect with the closed end of the barrel; it must be in full contact with a maximum conductance. Secret: Inserting place slightly rotated to have all strands at alignment. ? 4. Apply an Appropriate Crimping Tool A crimping tool must be of good quality and to fit with lug and cable size. Put a strong, even pressure on lug barrel to compress the cable. Donot use pliers, hammers or homemade tools as it will result in crimping irregularities and loose joints. In case of large cables, employ a hydraulic crimping tools to obtain more control and power. ? 5. Apply Optional but Recommended Heat Shrink Tubing (Optional) following crimping, cover the lug barrel with heat shrink tubing, and a small amount of cable insulation. This gives it extra insulation, moisture protection and eases the joint. ? 6. Secure Connection on Terminal To hang the lug on the busbar or the terminal block the connection must be tight and secure. Apply the recommended torque settings. Arcing could be a result of loose connection and this is a source of fire. General Installing Dos and Donots: Ensuring that the wrong size lug or cable is used Failing to insert the cable to the bottom of the lug Poor or bad crimping Not insulating or using protective sleeves Failure to clean oxidized surfaces prior to connection ???? Conclusion: There is a need to ensure proper installation of copper cable lugs to get safe, reliable and durable electrical connections. A proper way of doing things does not only enhance performance, but also avoids the expensive system breakdowns and safety risks. Quality lugs which are easy to install and last long, Pioneer Power International, has it all.

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