DTL-1
Mingxu
This precision-engineered connector addresses the challenges of dissimilar metal joining by incorporating a friction-welded interface between high-purity copper and aluminum, eliminating galvanic corrosion that plagues traditional connection methods. Compliant with IEC 61238-1:2003 standards, the DTL-1 ensures consistent electrical performance and mechanical stability in diverse terminal applications, from control panels to industrial machinery. Its compact design makes it particularly suitable for installations where space constraints demand reliable performance in limited areas.
The DTL-1 features a 99.9% electrolytic tough pitch (ETP) copper palm for superior conductivity and a 99.5% electrical-grade aluminum barrel (1060 alloy) for compatibility with aluminum conductors. The friction welding process creates a molecular bond between metals with weld strength exceeding 200 MPa, ensuring the joint outperforms the conductor itself under tensile stress.
With a contact resistance below 10 µΩ, the lug minimizes energy loss and heat generation during current transmission. It accommodates conductor cross-sections from 16 mm² to 240 mm² and operates within a temperature range of -40°C to 150°C, suitable for both ambient and elevated temperature environments.
Clear markings on the aluminum barrel indicate precise crimping locations, ensuring proper tool alignment during installation. The barrel design incorporates a chamfered entry to facilitate conductor insertion without damaging strands, while the copper palm features standardized bolt hole sizes (M6 to M24) for compatibility with common terminal configurations.
In manufacturing facilities, the DTL-1 connects aluminum power cables to copper busbars in motor control centers (MCCs), programmable logic controllers (PLCs), and variable frequency drives (VFDs). Its narrow palm design fits easily in crowded control panels with limited clearance.
The lug is widely used in commercial electrical systems for connecting distribution panels to branch circuits, lighting fixtures, and HVAC equipment. It provides reliable terminations in both exposed and concealed installations, including ceiling plenums and equipment rooms.
Solar inverter connections and wind turbine control systems utilize the DTL-1 for transitioning between aluminum array cables and copper terminals in combiner boxes and power conversion equipment. Its corrosion resistance ensures long-term performance in outdoor and rooftop installations.
The lug’s friction-welded bimetallic construction creates a stable interface where aluminum conductors connect to the aluminum barrel and copper terminals connect to the copper palm, eliminating direct contact between dissimilar metals. This configuration, combined with anti-oxidation compounds in the barrel, prevents electrochemical reactions that cause corrosion.
Proper installation requires stripping conductors to the specified length, applying anti-oxidation paste to aluminum conductors, inserting the conductor fully into the barrel, and crimping with a die-matched hydraulic tool. Two crimps are recommended for conductors larger than 50 mm², positioned according to the markings on the barrel.
No, the lug is designed for one-time crimping. Reusing or re-crimping may compromise the electrical and mechanical integrity of the connection. Always replace the lug when disconnecting and reconnecting conductors to ensure reliable performance.
The DTL-1 complies with IEC 61238-1:2003 (international standard for cable terminations) and UL 486A/B (Underwriters Laboratories standards for electrical connectors). These certifications validate its performance under various load, temperature, and environmental conditions.
| ltem No. | φ±0.3 | D±0.2 | d±0.2 | L±2 | L1±2 | W±0.2 | S±0.2 | Package (pcs) | Gross weight (kg) |
| DTL-1-10 | 8.5 | 10 | 5.2 | 65 | 30 | 16 | 2.2 | 1440 | 17.0 |
| DTL-1-16 | 8.5 | 11 | 6.1 | 70 | 31 | 16 | 2.2 | 1200 | 16.5 |
| DTL-1-25 | 8.5 | 12 | 7.1 | 75 | 35 | 18 | 2.8 | 960 | 17.5 |
| DTL-1-35 | 10.5 | 14 | 8.5 | 85 | 38 | 20.5 | 3.0 | 720 | 16.0 |
| DTL-1-50 | 10.5 | 16 | 9.8 | 90 | 42 | 23 | 3.4 | 540 | 21.0 |
| DTL-1-70 | 12.5 | 18 | 11.5 | 102 | 47 | 26 | 3.6 | 360 | 18.0 |
| DTL-1-95 | 12.5 | 21 | 13.5 | 112 | 51 | 28 | 4.2 | 240 | 16.5 |
| DTL-1-120 | 14.5 | 23 | 15.0 | 120 | 53 | 30 | 4.8 | 180 | 16.5 |
| DTL-1-150 | 14.5 | 25 | 17.0 | 126 | 56 | 34 | 5.3 | 180 | 20.5 |
| DTL-1-185 | 16.5 | 27 | 18.6 | 133 | 58 | 37 | 5.8 | 120 | 17.5 |
| DTL-1-240 | 16.5 | 30 | 21.5 | 140 | 60 | 40 | 6.0 | 96 | 21.0 |
| DTL-1-300 | 18.0 | 34 | 23.5 | 165 | 66 | 45 | 7.0 | 72 | 18.0 |
| DTL-1-400 | 21.0 | 38 | 26.5 | 178 | 76 | 50 | 54 | 19.0 | |
| DTL-1-500 | 21.0 | 45 | 29.5 | 200 | 85 | 55 | 48 | 20.0 | |
| DTL-1-630 | 50 | 32.5 | 225 | 85 | 60 | 48 | 21.0 | ||
| DTL-1-800 | 60 | 37.0 | 270 | 90 | 100 | 36 | 22.0 |
This precision-engineered connector addresses the challenges of dissimilar metal joining by incorporating a friction-welded interface between high-purity copper and aluminum, eliminating galvanic corrosion that plagues traditional connection methods. Compliant with IEC 61238-1:2003 standards, the DTL-1 ensures consistent electrical performance and mechanical stability in diverse terminal applications, from control panels to industrial machinery. Its compact design makes it particularly suitable for installations where space constraints demand reliable performance in limited areas.
The DTL-1 features a 99.9% electrolytic tough pitch (ETP) copper palm for superior conductivity and a 99.5% electrical-grade aluminum barrel (1060 alloy) for compatibility with aluminum conductors. The friction welding process creates a molecular bond between metals with weld strength exceeding 200 MPa, ensuring the joint outperforms the conductor itself under tensile stress.
With a contact resistance below 10 µΩ, the lug minimizes energy loss and heat generation during current transmission. It accommodates conductor cross-sections from 16 mm² to 240 mm² and operates within a temperature range of -40°C to 150°C, suitable for both ambient and elevated temperature environments.
Clear markings on the aluminum barrel indicate precise crimping locations, ensuring proper tool alignment during installation. The barrel design incorporates a chamfered entry to facilitate conductor insertion without damaging strands, while the copper palm features standardized bolt hole sizes (M6 to M24) for compatibility with common terminal configurations.
In manufacturing facilities, the DTL-1 connects aluminum power cables to copper busbars in motor control centers (MCCs), programmable logic controllers (PLCs), and variable frequency drives (VFDs). Its narrow palm design fits easily in crowded control panels with limited clearance.
The lug is widely used in commercial electrical systems for connecting distribution panels to branch circuits, lighting fixtures, and HVAC equipment. It provides reliable terminations in both exposed and concealed installations, including ceiling plenums and equipment rooms.
Solar inverter connections and wind turbine control systems utilize the DTL-1 for transitioning between aluminum array cables and copper terminals in combiner boxes and power conversion equipment. Its corrosion resistance ensures long-term performance in outdoor and rooftop installations.
The lug’s friction-welded bimetallic construction creates a stable interface where aluminum conductors connect to the aluminum barrel and copper terminals connect to the copper palm, eliminating direct contact between dissimilar metals. This configuration, combined with anti-oxidation compounds in the barrel, prevents electrochemical reactions that cause corrosion.
Proper installation requires stripping conductors to the specified length, applying anti-oxidation paste to aluminum conductors, inserting the conductor fully into the barrel, and crimping with a die-matched hydraulic tool. Two crimps are recommended for conductors larger than 50 mm², positioned according to the markings on the barrel.
No, the lug is designed for one-time crimping. Reusing or re-crimping may compromise the electrical and mechanical integrity of the connection. Always replace the lug when disconnecting and reconnecting conductors to ensure reliable performance.
The DTL-1 complies with IEC 61238-1:2003 (international standard for cable terminations) and UL 486A/B (Underwriters Laboratories standards for electrical connectors). These certifications validate its performance under various load, temperature, and environmental conditions.
| ltem No. | φ±0.3 | D±0.2 | d±0.2 | L±2 | L1±2 | W±0.2 | S±0.2 | Package (pcs) | Gross weight (kg) |
| DTL-1-10 | 8.5 | 10 | 5.2 | 65 | 30 | 16 | 2.2 | 1440 | 17.0 |
| DTL-1-16 | 8.5 | 11 | 6.1 | 70 | 31 | 16 | 2.2 | 1200 | 16.5 |
| DTL-1-25 | 8.5 | 12 | 7.1 | 75 | 35 | 18 | 2.8 | 960 | 17.5 |
| DTL-1-35 | 10.5 | 14 | 8.5 | 85 | 38 | 20.5 | 3.0 | 720 | 16.0 |
| DTL-1-50 | 10.5 | 16 | 9.8 | 90 | 42 | 23 | 3.4 | 540 | 21.0 |
| DTL-1-70 | 12.5 | 18 | 11.5 | 102 | 47 | 26 | 3.6 | 360 | 18.0 |
| DTL-1-95 | 12.5 | 21 | 13.5 | 112 | 51 | 28 | 4.2 | 240 | 16.5 |
| DTL-1-120 | 14.5 | 23 | 15.0 | 120 | 53 | 30 | 4.8 | 180 | 16.5 |
| DTL-1-150 | 14.5 | 25 | 17.0 | 126 | 56 | 34 | 5.3 | 180 | 20.5 |
| DTL-1-185 | 16.5 | 27 | 18.6 | 133 | 58 | 37 | 5.8 | 120 | 17.5 |
| DTL-1-240 | 16.5 | 30 | 21.5 | 140 | 60 | 40 | 6.0 | 96 | 21.0 |
| DTL-1-300 | 18.0 | 34 | 23.5 | 165 | 66 | 45 | 7.0 | 72 | 18.0 |
| DTL-1-400 | 21.0 | 38 | 26.5 | 178 | 76 | 50 | 54 | 19.0 | |
| DTL-1-500 | 21.0 | 45 | 29.5 | 200 | 85 | 55 | 48 | 20.0 | |
| DTL-1-630 | 50 | 32.5 | 225 | 85 | 60 | 48 | 21.0 | ||
| DTL-1-800 | 60 | 37.0 | 270 | 90 | 100 | 36 | 22.0 |
