Copper Crimp Lug for Power​

Product Overview

Precision-machined from high-purity copper, this crimp lug ensures low-resistance terminations for copper conductors in medium to high-voltage applications, where power loss minimization and connection stability are critical. Compliant with UL 486A/B and IEC 61238-1 standards, it meets rigorous safety and performance requirements for utility substations, industrial power systems, and critical facility electrical networks. Its robust construction supports continuous operation under heavy electrical loads and harsh environmental conditions.

Product Features

High-Purity Construction

Manufactured from 99.9% electrolytic tough pitch (ETP) copper, the crimp lug achieves exceptional electrical conductivity of ≥97% IACS, ensuring minimal power loss at connection points. The copper material's high ductility allows for uniform deformation during crimping, creating a gas-tight seal between conductor and lug that prevents oxidation and corrosion within the connection interface.

Performance Capabilities

The lug accommodates conductor cross-sections from 16 mm² to 300 mm² and supports current ratings up to 600A for the largest size under ambient temperature conditions (30°C). It maintains stable performance across an extreme temperature range of -50°C to 150°C, making it suitable for both indoor equipment rooms and outdoor installations. The crimped connection achieves a tensile strength exceeding 180 MPa, ensuring conductor retention even under mechanical stress or thermal cycling.

Enhanced Design Features

Featuring a tinned copper surface finish (5-10 µm thickness), the lug provides superior corrosion resistance compared to bare copper, particularly in high-humidity or industrial environments. The conductor barrel incorporates longitudinal serrations that enhance mechanical grip and electrical contact when crimped. Precision-machined terminal holes with standardized dimensions (M6 to M20) ensure compatibility with common busbar and equipment terminals, facilitating versatile installation.

Product Applications

Utility Substation Infrastructure

In electrical substations, the Copper Crimp Lug terminates high-current copper conductors in busbar systems, transformer bushings, circuit breakers, and disconnect switches. Its high current capacity and low resistance make it ideal for bulk power transmission applications up to 33 kV.

Heavy Industrial Power Systems

Steel mills, chemical plants, and mining operations utilize these lugs for connecting power cables to large motors, switchgear, and distribution panels. Their robust construction withstands the high vibration, temperature fluctuations, and industrial contaminants common in heavy manufacturing environments.

Critical Facility Electrical Networks

Data centers, hospitals, and emergency power systems rely on these copper crimp lugs for their high-reliability connections in backup generator systems, UPS (Uninterruptible Power Supply) installations, and critical power distribution pathways. Their low resistance ensures minimal voltage drop in mission-critical electrical circuits.

FAQ

What distinguishes ETP copper from other copper alloys used in crimp lugs?

ETP copper (C11000) offers the highest electrical conductivity among commercially available copper alloys, making it ideal for power applications where minimizing energy loss is essential. While other copper alloys may provide greater mechanical strength, they typically sacrifice conductivity, making ETP copper the preferred choice for high-current connections.

What crimping specifications should be followed for optimal performance?

Proper installation requires using hexagonal crimp dies matched to the conductor size, applying sufficient force to achieve 85-90% compression of the conductor strands. Consult the manufacturer's datasheet for specific crimp dimensions and tool requirements, as improper crimping can result in increased resistance or mechanical failure.

How does the tinned finish enhance performance?

The tin plating provides a barrier against oxidation and corrosion, extending connection life in harsh environments. It also facilitates soldering if required for additional connection security, and reduces contact resistance by providing a uniform, low-oxide interface between mating surfaces.

Are these lugs suitable for outdoor installations?

Yes, the tinned copper finish and robust construction make them suitable for outdoor use. For exposed installations in coastal or highly polluted areas, additional protective measures such as heat-shrink tubing with adhesive lining are recommended to further enhance corrosion resistance.