Installing and crimping bi-metallic lugs is a meticulous process aimed at creating safe, reliable, and long-lasting electrical connections between aluminum cables and copper terminals. This technique is commonly used in both industrial and commercial environments, with suppliers like Pioneer Power International offering comprehensive guidelines to ensure everything is done right.
The installation kicks off with preparing the cable: strip away the insulation to reveal the conductor, making sure the stripped length aligns with the internal length of the bi-metallic lug barrel. A light polish on the conductor's surface helps eliminate any oxide layer or dirt, which enhances electrical contact and minimizes resistance. To further combat oxidation and guarantee optimal conductivity, apply an oxide breaker or anti-oxidation compound evenly on the conductor and inside the barrel.
Next, fully insert the prepared conductor into the aluminum barrel of the bi-metallic lug, ensuring that all strands are seated correctly and that no conductor is left exposed. When it comes to crimping, grab a suitable crimping tool with the right die size for both the cable and the lug. Start by making the first crimp about 5mm from the end of the barrel nearest to the copper palm, and then add more crimps at recommended intervals along the barrel to secure a solid mechanical and electrical connection. Remember to apply moderate, steady pressure while crimping to avoid damaging either the lug or the conductor.
Once you've crimped, give the connection a gentle pull test to make sure it's secure. For added protection and durability, cover the crimped joint with heat shrink tubing or insulating tape, ensuring it envelops the entire aluminum barrel and part of the cable jacket. Finally, double-check the connection for tightness and make sure the bi-metallic lug is bolted firmly to the copper terminal or bus bar. By following these steps, as outlined by Pioneer Power International, you can be confident that bi-metallic lugs will provide safe, efficient, and durable connections, even in the toughest electrical applications.