Bimetallic Cable Lug
Bimetallic cable lug intended to transition between a conductor and connection surface made from dissimilar metals.
A bimetallic cable lug is used, for example, to connect an aluminium conductor to a copper busbar or terminal without forming an uncontrolled direct Al–Cu interface.
The barrel and connection palm are made from different metals and joined using a specialised process such as friction welding. The aluminium section is commonly factory-filled with oxide-inhibiting compound.
Important characteristics include material and grade of both sections, plating, bimetal transition method and barrel/palm geometry. Incorrect selection can lead to galvanic corrosion and increased joint resistance.
Selection should consider conductor material and size, busbar material, transition method, plating, joint compound, connection-hole geometry and IEC 61238-1-1/-1-3 compliance.
Bimetallic cable lugs for aluminium-to-copper and other dissimilar-material connections.
Bimetallic Cable Lug
General3
Commercial or technical designation of a manufacturer's product family sharing a common design and compatible characteristics.
Range of tasks and systems for which the manufacturer recommends the component.
Primary function of the device and its intended use as defined by its design and the manufacturer's documentation.
Dimensions15
External horizontal dimension of the product between its outermost lateral points.
External vertical dimension of the product from its lowest to its highest point.
External distance between the foremost and rearmost surfaces of the product.
External linear dimension of the product along its longitudinal direction or principal length axis.
Dimension of a material, part, or product between two opposite surfaces, measured in the thickness direction.
Transverse dimension of a product or its circular element measured through the centre between opposite points of the circumference.
Axial length of the conductor crimp barrel or crimping zone.
Nominal internal diameter of the conductor receiving barrel or sleeve before installation.
Nominal external diameter of the conductor barrel or sleeve.
Overall width of the cable-lug palm or connection tongue.
Axial length of the flat cable-lug palm or connection tongue.
Thickness of the cable-lug palm or connection tongue.
Number of mounting or connection holes in the cable-lug palm.
Nominal diameter of the mounting hole of a compatible cable lug for installation on the terminal bolt or stud.
Centre-to-centre spacing between repeated connection holes in a multi-hole cable lug.
Materials and Finish17
Primary material of the internal current-carrying part, bridge, busbar, or other conductive element of the product.
Grade, alloy designation, or other declared material designation of the main current-carrying part.
Metallic plating of the principal current-carrying part, different from its base material.
Type of final surface finish of the product determining its appearance and service properties.
Thickness of the coating layer applied to the surface of the product or one of its parts.
Material of the conductor barrel or sleeve forming the primary conductor receiving portion of the connector or cable lug.
Manufacturer-declared alloy, temper or material grade of the conductor barrel or sleeve.
Metallic plating or surface metallization applied to the conductor barrel or sleeve.
Material of the flat palm, pad or connection tongue of a cable lug.
Manufacturer-declared alloy, temper or material grade of the cable-lug palm or connection tongue.
Metallic plating applied to the cable-lug palm or connection tongue.
Indicates whether functional or protective electrical insulation is provided over all or part of the conductive surface of the product.
Primary electrical insulation material applied to or integrated with the conductive part of the product.
Color of the primary electrical insulation layer surrounding the conductor.
Extent of electrical insulation coverage over the conductive part of the product.
Manufacturing method used to join dissimilar metallic sections of a bimetallic cable lug or connector.
Primary grease, oxide inhibitor or conductive joint compound used at the conductor interface.
Electrical Parameters23
Voltage value assigned to the product by the manufacturer for specified application conditions and characteristics.
Maximum voltage at which continuous operation of the product is permitted under the conditions declared by the manufacturer.
Current assigned to the product by the manufacturer for the declared operating and thermal conditions.
Voltage with reference to which the product's insulation clearances and dielectric properties are specified.
Test voltage applied to verify the dielectric strength of the product insulation.
Manufacturer-declared nominal conductor cross-section assigned to the relevant connection system.
Minimum conductor cross-section permitted by the connection system within its general conductor-size range.
Maximum conductor cross-section permitted by the connection system within its general conductor-size range.
Conductor materials for which the specified terminals and connection methods are designed.
Conductor construction classes permitted by the product's electrical connection system.
Conductor connection methods supported by the specified terminals or connection elements.
Declared electrical contact resistance of a connection point where one common value applies to equivalent connections.
Minimum rigid conductor cross-section permitted by an electrically and mechanically equivalent connection point.
Maximum rigid conductor cross-section permitted by an electrically and mechanically equivalent connection point.
Minimum flexible conductor cross-section permitted by the relevant connection point.
Maximum flexible conductor cross-section permitted by the relevant connection point.
Mechanical barrel style of a crimp termination, such as open-barrel or closed-barrel.
Manufacturing construction of the crimp barrel, such as seamless or seamed.
Manufacturer-declared crimp geometry or die profile used to form the electrical connection.
Minimum manufacturer-declared axial pull-out force of the completed crimp connection under the specified test conditions.
RMS value of short-time withstand current Icw that the product can withstand for the declared duration without unacceptable damage.
Duration for which the product must withstand the declared short-time current.
Peak current value Ipk that the product can withstand under the declared short-circuit conditions.
Protection and Safety1
Degree of enclosure protection against access to hazardous parts and ingress of solid objects and water, designated by the IP code.
Environmental Conditions8
Minimum ambient temperature at which normal operation of the product is permitted.
Maximum ambient temperature at which normal operation of the product is permitted.
Minimum ambient temperature permitted during storage of the product while not in operation.
Maximum ambient temperature permitted during storage of the product while not in operation.
Environmental corrosivity category for which resistance of the product material or protective coating is declared.
Duration of salt-spray testing withstood by the product or coating under the declared conditions.
Indicates whether the product materials retain their declared properties when exposed to the specified oils.
Indicates whether the material and coating are designed to withstand ultraviolet radiation.
Included Equipment2
Manufacturer tool family, tool model or tooling system declared compatible with the crimp termination.
Manufacturer designation of the crimp die, insert or die set required for the declared crimp.
Special Features9
Total number of electrical connection points provided by the product.
Indicates that the electrical connection can be intentionally opened and remade without replacing the connector, under the manufacturer-declared conditions.
Indicates whether conductor insulation must be removed before the conductor is inserted or terminated in the connector.
Number of separate conductor insertion entries provided by the termination accessory.
Indicates that the crimp barrel or sleeve includes a physical stop controlling conductor insertion depth.
Indicates that the termination provides an opening or window for visual verification of conductor insertion.
Geometric orientation between the conductor crimp axis and the mating or connection portion of the terminal.
Primary mechanical form of the terminal mating or connection portion.
Indicates that the connector or lug is factory-filled or supplied with an oxide-inhibiting compound for the conductor interface.
Standards and Compliance11
Primary normative document or standard according to which the manufacturer classifies or assesses the product.
Additional normative documents and standards declared by the manufacturer as applicable to the product.
Indicates whether the product has a declared UL Listed certification or recognition status.
Indicates whether the product has a declared UL Recognized certification or recognition status.
Indicates whether the product has a declared CSA certification or recognition status.
Indicates whether product compliance with applicable RoHS restrictions on hazardous substances has been declared.
Indicates whether the manufacturer declares compliance of the product with applicable REACH Regulation requirements.
Manufacturer-declared compliance with IEC 60352-2 requirements for solderless crimped connections where applicable.
Manufacturer-declared compliance with UL 486A-486B requirements for wire connectors and termination components where applicable.
Manufacturer-declared compliance with IEC 61238-1-1 for compression and mechanical connectors for power cables up to 1 kV tested on non-insulated conductors, where applicable.
Manufacturer-declared compliance with IEC 61238-1-3 for compression and mechanical connectors for power cables above 1 kV up to 30 kV tested on non-insulated conductors, where applicable.
Logistics6
Mass of the product itself, excluding transport packaging, additional accessories, and external equipment.
Number of individual products contained in one packaging unit at the specified level.
Design type of the product's individual or transport packaging.
Country of origin of the goods declared for customs or commercial purposes.
Commodity code under the international Harmonized Commodity Description and Coding System.
Commodity code under the Combined Nomenclature of the European Union.