Choice Of Cable Lugs
Choosing the right cable lug is essential to ensuring a clean, secure, and long-lasting connection. Here’s what to look out for when selecting cable lugs for copper conductors — covering conductor class, standards, and testing for safety and quality.
1. Conductor Classes & Matching Lug Types
Cable lugs for copper conductors come in various types depending on the conductor class (per DIN EN 60228). • For Class 1, 2, 5, and 6 conductors, you have compression cable lugs according to DIN 46235. • Class 2 conductors can use standard tubular cable lugs. • Classes 2, 5, and 6 also use solderless terminals per DIN 46234. Choosing a lug compatible with the conductor class ensures better mechanical and electrical performance.
2. Crimping Die Standards
For safe and consistent crimps, when using DIN compression cable lugs, tools with coded dies according to DIN 48083-4 are recommended. These dies ensure correct form and pressure during crimping. Always follow the manufacturer’s requirement for tubular lugs.
3. Solderless Terminals & Indent Crimping
Solderless terminals (DIN 46234) are processed using the indent crimping method. This offers a way to crimp without solder, reducing risk of hot spots and improving long-term reliability when done properly.
4. Quality & Resistance Testing
Cable lugs must meet electrical and mechanical criteria under IEC 61238-1 part 1. Tests include electrical durability, mechanical tension, high current & temperature cycling, and short-circuit ability. These tests simulate real life ageing and mechanical stresses to ensure safety and reliability.
5. Additional Quality Measures (Beyond Standards)
Cablectrix adds further quality checks beyond standard requirements: many of our lugs (e.g. from Klauke) are annealed to reduce hardness and internal stress, ensuring better ductility and reduced risk of failure during crimping. Clean, burr-free machining and a flat palm are visual signs of high quality.
6. Visual & Physical Inspections
Before use, inspect cable lugs visually: look for consistent flat palm, no burrs, clean tube section, and proper finish. These factors may not affect performance immediately but often indicate manufacturing integrity and long-term performance.
7. Certifications & Regulatory Compliance
Many cable lugs supplied are UL tested/certified, especially important for North American use. Combined with international standards like IEC 61238-1, these certifications help ensure safety, compatibility, and reliable performance globally.
