The No.1 Cable Lug Manufacturer – Rayphen
All Rayphen cable lug guarantee 100% inspection during the manufacturing method.

Why Rayphen Cable Lug

Improve Your Business with Rayphen Cable Lug

All Rayphen cable lug guarantee 100% inspection during the manufacturing method.

Copper Cable Lugs

As a professional copper lugs manufacturer, Rayphen offers a wide selection of LV cable lug, MV cable lug, or HV cable lug. You can choose either tinned copper lugs or bare copper cable lugs. And you can choose 2 hole compression lug or 90 degree cable lug. Contact us now to get a quick quote for your copper lugs.

Bimetal Cable Lug

Select various standards of bimetal cable lug at Rayphen! Such as DIN, IEC, NFC, etc. The bimetal cable lug is made of high-quality aluminum and copper. In order to prevent oxidation, you can choose a bimetal cable lug to fill with grease. Rayphen manufactures top-quality bimetal cable lug at a very affordable price.

Aluminum Cable Lugs

At Rayphen, The aluminum cable lugs are suitable for conductor cross-section from 10mm2 to 500mm2. And aluminum cable lugs are suitable for both outdoor and indoor applications. For your special application needs, we can also customize your ideal aluminum lug.

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Copper Cable Lugs
Type NoMain DimensionsType NoMain Dimensions

Bimetal Cable Lug
Bolt SizeDdLL1
CAL-16AM8 M10165.58342
CAL-25AM8 M10166.58342
CAL-35AM8 M101688342
CAL-50AM8 M102099043
CAL-70AM10 M1220119043
CAL-95AM10 M122012.59043
CAL-120AM10 M122513.511560
CAL-150AM10 M122515.511560
CAL-185AM10 M12 M163217.512260
CAL-240AM10 M12 M163219.512260
CAL-300AM12 M16 M203422.512562

Aluminum Cable LugsAluminum Cable Lugs
Type No.Main Dimensions(mm)Type No.Main Dimensions(mm)

TypeConductor Cross-section(mm2)DimensionsNumber of Bolts
BML 25-9525-952412.86013/171
BML 35-15035-1502815.88613/171
BML 95-24095-240332011213/172
BML 120-300120-300372411513/172
BML 185-400185-4004225.513713/17/213
BML 500-630500-630503315013/17/213

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Rayphen Cable Lug

Rayphen takes the lead in supplying and manufacturing excellent quality cable lug. We have approximately 14 years of experience in providing cable lug solutions.

We are providing a complete range of cable lug such as electrical cable lugs, connection lugs, power cable lugs, kabel lugs, and many more.

Rayphen cable lug features a correct fit that guarantees your total safety and installation. It has also constant material thickness, precise diameter, and it is available in the standard range.

We have an extensive range of designs, end-to-end engineering, lug solutions, manufacturing solutions, and equipment building industries.

To get more information regarding Rayphen cable lugs, get in touch with us!

Why Rayphen Cable Lugs

Rayphen is a reliable lug supplier and manufacturer for almost 14 years. We have abundant cable lugs, electrical cable lugs, and power cable lugs that can be distributed everywhere in the country.

Choosing the exact cable lug depends on the conductor class. Rayphen is offering all types and standards of cable lugs such as compression cable lugs, heavy duty cable lugs, tubular cable lugs, high voltage cable lugs, electrical cable lugs, and etc.

Rayphen cable lug is made of seamless 99.% purity copper or 99.5% purity aluminum. We anneal the material. To be precise, annealing is a heat treatment process for materials, in order to reduce deformation and cracks. The most important thing is that we will check the hardness for you after annealing, copper HB≤62, aluminum HB≤25.

Rayphen cable lug is made of the best quality copper, aluminum, or bimetal which makes it suitable with copper conductors and aluminum connectors for connecting the hemicycle-sector wire and round wire.

According to different conductor material applications. Rayphen offers copper cable lugs, aluminum cable lug, bimetal cable lugs, shear bolt lug, and pre-insulated lug.

We are dedicated to manufacturing and supplying the country with our very affordable and high-quality cable lug. We are focused on designing, developing, and producing different types of cable lug.

At Rayphen, in order to avoid oxidation. You can choose the cable lug with grease. In addition, The cable lug surface treatment can be tin-plated or not. And The thickness is usually greater than 3 microns, but we can reach greater than 20 microns

You can guarantee the excellent performance, durability, long service life, and quality of Rayphen cable lugs because of its advanced manufacturing process. The process includes cutting, annealing, acid cleaning, welding, lathe, stretching, coating, forging, and etc.

We guarantee you the aesthetic design and standard of our cable lug products because of the help of our professional, experienced engineers, and our advanced equipment.

Rayphen cable lug products are designed, verified, and tested in accordance with IEC, BS, NFC, DIN, and ISO9001 quality management systems.

You can send a specific design of cable lug and we will be glad to give a solution. We are passionate about giving excellent service to our customers.

Get your high-quality cable lug at a competitive price only at Rayphen!

Cable Lug FAQs—The Ultimate Guide

Whenever someone talks about electrical connectors, cable lug is the name that pops up in your mind. Yes, the most widely used electrical connector alongside other connectors. It has so many applications with the basic purpose of connecting wires of different sorts with each other.

You must have so many questions in mind regarding cable lugs. Don’t worry. We have all made it up under one roof. Here is the ultimate cable lug question answer guide.

It includes every single detail about your cable lug and if you are planning to buy one, you are at the perfect spot. We will tell you its installation, maintenance, working, purpose, advantages, features, and much more.

Let’s start with the basic questions to the hard ones!

Q1. What is Cable Lug?

Cable lugs are electrical connectors designed for making connections between cables and electrical devices, appliances, surfaces, cables, and mechanisms.

Cable Lug                                                                        Figure 1 Cable Lug

Some companies may name cable lug as mechanical lug.

It also acts as a terminal for joining the cable edges and to make termination.

Clamps that join the cable or wire with car batteries are a good example of a cable lug.

Rayphen cable lug is quick and easy to install and has a compact size.

The dimensions of the cable lug are so well that they completely seal the connection between two electrical things whether cables or electrical appliances.

There are different styles and sizes of cable lugs; you can ask whatever suits your need.

Sometimes, people misunderstand the meaning of cable and wire. They think of the two as the same things.

Perhaps, they are different. The cable contains a cluster of wire strands in it whereas wire is a single strand.

The cable lug not only supports the cables as its name indicates; it works perfectly well with wires too.

Q2. What is the Purpose of Cable Lug?

There are so many purposes for cable lug.

We will briefly tell you each one of them turn-wise.

In electrical industries, cable lugs serve the purpose of linking two similar cables or forming a connection between a cable and some electrical appliance.

It is not only employed to connect electrical devices but also fuses sockets and switches.

The cable lug also has an application within power lines and transmission lines.

For extremely high voltages, a special type compression lug comes in use as compared to simple cable lugs.

Due to its usage in making electrical connections, cable lug is available with insulation layering or sheets so to increase the safety to the maximum.

Rayphen cable lugs having unique features, configurations and styles have applications with automobiles, electrical wiring, instruments, and control panels.

Most of the commonly used cable lug is copper cable lug being convenient to install and compatible with conductors for multiple connections.

For most purposes and applications, using the correct cable lug is imperative.

Always choose a suitable cable lug before using it for any industry.

Q3. What are the Types of Cable Lug?

Generally, cable lugs have two categories having different types in each.

One of them is of application and design whereas the other is based on manufacturing material.

We will discuss each category separately.

There are four types of cable lugs based on the difference in application and design.

Each has a different design and functioning.

The basic working principle remains the same but they differ in their applications.

Let us discuss each type in detail.

  • Ring Type Cable Lug

The ring-type cable lug is used in the area having nuts and bolts. It is also known as a roundhead cable lug.

It has a ring head attached to the cable lug barrel.

For air circuit breaker (ACB), miniature circuit breaker (MCB), oil circuit breaker (OCB), and molded case circuit breaker (MCCB) ring-type cable lug is ideal to use.

Their insulation layering is also available in yellow, red, green, and blue colors.

The diameter of the barrel depends on the diameter of the bolt.

Ring Cable Lug with Insulation Cover                                                                Figure 2 Ring Cable Lug

  • U Type Cable Lug

The U type cable lug is employed at relays, contactors, MCB, and timers.

This type has U shaped head that looks similar to the wrench face.

It also has insulation of yellow, red, blue, and other colors.

U-Type Cable Lug                                                                           Figure 3 U-Type Cable Lug

  • Pin Type Cable Lug

This type of Rayphen cable lug is mostly seen at terminal blocks.

It has a pinhead instead of a hoop along with a barrel.

Pin Type Cable Lug                                                         Figure 4 Pin Type Cable Lug

  • Boot Lace Type Cable Lug

The boot lace type cable lugs are used for the cables of instruments and their control panels.

It also has a pin shaped head but it is different from the pin of pin type cable lug.

Its pin is thinner and has a narrow ending at the place of the barrel connection.

Boot Lace Cable Lug                                                               Figure 5 Boot Lace Cable Lug

Now, we will discuss the type of cable lug based on manufacturing material.

  • Aluminum Cable Lug

Those cable lugs having a head and barrel of aluminum.

  • Copper Cable Lug

The cable lug is manufactured of copper.

  • Bimetal Cable Lug

The cable lug that has the head of different material and barrel of different material is termed as bimetal cable lug.

Some mechanical cable lugs have double features of shear bolt connector and cable lug combined.

It has a ring head having a barrel but with bolts on it.

There are cable lugs having a side palm, center palm, and holes as well.

Rayphen has a variety of such cable lugs that are very conveniently available.

Q4. Which Materials are Used for Manufacturing Cable Lugs?

Basically, there are two materials that are very much in use for producing high-end cable lugs.

They are aluminum and copper.

Stainless steel cable lugs are also available but they are not a preferable option to get.

Most popular are copper and aluminum cable lugs.

Let’s see why aluminum and copper make such good manufacturing materials.

  • Aluminum

It is a non-toxic metal having a low density.

Being highly thermostable, aluminum goes under processing and still maintains its shape.

Also, it has an extraordinary corrosion-free property and is malleable.

You can forge it into different shapes and designs as you like.

Aluminum is non-sparking as well as non-magnetic.

  • Copper

Copper has excellent stability against electricity and heat. It means it is stable electrically and thermally.

It has good machinability and is nonmagnetic.

Like aluminum, copper can also cast into different shapes and designs.

Also, you know that copper is a really good conductor of the electric current itself. When the copper barrel combines with the copper conductor, the flow becomes smooth and steady.

Q5. How to Choose the Perfect Cable Lug?

Getting the perfect product for your business is the top contributor to its success.

There are certain points that make it easier for you to choose the right Rayphen cable lug.

These few key points are as under.

  • Match the rating of the temperature of the cables and the cable lug.
  • Choose cable lug according to the right dimensions of the cable or wire.
  • If the cable needs crimping, do it with the proper tool before joining.
  • Keep in mind for which application you are getting cable lug. Choose accordingly.
  • Ensure genuine 99.95%aluminum or copper or both are used in the manufacturing of cable lug.

All these considerations will help you get the perfect cable lug.

Q6. How Does a Cable Lug Work?

The Rayphen cable lug’s one end is used for making the connection with a device or cable.

That end is usually crimped, soldered, or welded so that to adjust the cable lug with the cable of the electrical device.

To the device’s connection terminal, the second end of the Rayphen cable lug is attached.

During its connection to the connection terminal, you need to fasten the bolts and nuts to make the connection secure and tight.

For making terminal connections, the spring clip comes into use.

Cable lugs have different uses depending on the application and the industry.

Q7. Where to Use Cable Lugs?

Rayphen Cable lugs are used in different circuit breakers, control panels of instruments, musical instruments cable connections, electrical appliances, automobiles, and electrical wiring.

As you get to know about the different types of cable lugs, you better know by now that they have applications in different industries especially wiring.

Q8. How to Properly Install a Cable Lug?

The installation procedure of cable lugs is very easy.

You can easily do it without any professional assistance or guidance.

Here are the quick installation steps.

  • With the help of striping pliers, strip the cable so that it can go into the barrel of the cable lug.
  • Remove the separator or any insulating layer from the conductor very carefully.

Cable Stripping                                                         Figure 6 Cable Stripping

  • If the cable strands have an oxidizing layer, remove it by applying a good quality oxide remover.
  • If the cable strands are without oxidative material on them, you can skip this part.
  • Apply some of the oxide breakers at the conductor ends and the barrel edges of the cable lug. It is helpful in decreasing the resistance of contact between the two.
  • Now, put the cable into the cable lug and by using a crimping tool, crimp the barrel so that the cable gets fixed tightly in the lug.

Cable Lug with Inserted Cable Being Crimped

                                                      Figure 7 Cable Lug with Inserted Cable Being Crimped

Completed Connection

                                                        Figure 8 Completed Connection

  • For secure sealing, put a heat shrink sleeve to stop dust and other particles come in contact with the back of the cable lug.

Applying Heat Shrink

                                                      Figure 9 Applying Heat Shrink

Q9. How to Fix Cable Lug with a Battery Cable?

Here is the easiest way to attach a Rayphen cable lug of any size to the battery cables.

You need few simple tools for that.

  • Hold open the crimper and put the cable lug in its mouth.
  • Once you do this, take the stripped cable and insert it into the cable lug that is already placed between the mouth of the crimper.
  • Now, with enough force, crimp the end of the barrel having a cable inside.
  • Cut some inches of a heat shrink and with a heat gun apply heat shrink to seal the attachment.

Q10. What are Some of the Technical Requirements of Cable Lugs Manufacturing?

There are few requirements for cable lug manufacturing. These are:

  • The dimensions must be according to the standard.
  • It should have appropriate markings on it.
  • The cable lugs should be made following international standards.

Keep these few things in mind when manufacturing a cable lug.

It will save you from difficulties and the product will be of good standard quality.

Q11. Can You Use Copper Cable Lugs for Aluminum Conductors?

No, you cannot use a copper cable lug for aluminum conductors.

It is mainly because there should be conductor compatibility with the cable lug.

The Rayphen copper cable lugs are for copper conductors.

For aluminum conductors, using an aluminum cable lug will be appropriate.

Also, you can use a bimetal lug with having an aluminum barrel and copper head/palm for connecting aluminum conductors.

Q12. What is the Correct Way to Crimp a Cable Lug?

Crimping a cable lug is a critical part of the installation process.

You have to select the appropriate crimping tool for that.

Place the crimper on a solid surface to make the punching easier for you.

Adjust the cable lug according to its size in the crimper.

Adjust it in a way so that its top face the indenting spike of the crimping tool.

Now, insert the cable into the Rayphen cable lug and crimp it.

Apply heat shrink for better sealing and connection.

Q13. What are the Key Characteristics of Aluminum Cable Lug?

Here are the key characteristics of an aluminum cable lug.

  • They are manufactured from 99.5% aluminum (pure).
  • Aluminum lugs are designed to get crimped on the conductors for terminal facilitation through the hole of the lug.
  • The barrel of the lug is capped and has oxide layering to prevent corrosion.
  • Their barrel is round it means if the conductors are not, you need to make them round first to insert into the cable lug.
  • The barrel of the aluminum cable lug is long and is tapered for easy insertion of cables.
  • It is perfect for conductors carrying a 1kV current.

Q14. Can You Use Cable Lugs for Switch Cabinets?

Yes, you can use a Rayphen cable lug (copper, aluminum, or bimetal) for switch cabinets.

The working area of most of the switch cabinets is small.

Cable Lugs in Switch Cabinet

                                                            Figure 10 Cable Lug in Switch Cabinet

It becomes very difficult to connect conductors or cables to switch gears.

In these cases, using a cable lug with a larger head or cross-sectional area is inappropriate.

To cope with the situation, manufacturers like Rayphen introduce narrow-headed cable lugs.

They are specially designed for closed working surfaces or areas such as switch cabinets.

The cable lug having a narrow palm is usually thicker than the standard one.

This is to keep the balance of manufacturing material used in them.

Whether you are making the palm narrow, you have to use enough copper or aluminum as required by a standard cable lug.

Q15. Is it Appropriate to Use Cable Lug for Aggressive Environment?

Yes, for aggressive environmental conditions you can use stainless steel cable lug or nickel tubular lugs.

The stainless steel mechanical lugs by Rayphen are resistant to acid as well as they are corrosion-free.

This makes their application mostly at those industries that are near water lands.

As they are very much in touch with seawater such as sailing yachts.

Stainless steel cable lugs can also tolerate high temperatures as high as 400°C.

For even higher temperatures such as furnaces where the temperature is 650°C, nickel cable lug is an appropriate call.

The indent crimper is suitable for both these cable lugs for proper crimping.

Q16. What is Cable Lug Price?

The price of a cable lug depends on its size and material.

If you are getting a cable lug for a large cable having a long barrel and head it can cost you US$1.00-US$100 per piece.

If the size is small, you can have them for US$0.10-US$2.00.

Q17. For Which Voltage Range Using a Cable Lug is Suitable?

Cable lugs are very convenient to use at low, medium, and high voltages.

They can pretty well at high voltage but they are specifically suitable to use for low voltage and medium voltages.

The cable lug works best with low voltage and medium voltage conductors.

Q18. Can You Get Cable Lugs in Various Sizes?

Yes, you can purchase cable lugs of various sizes at Rayphen.

It depends on your usage.

Cable Lugs in Various Sizes                                                                            Figure 11 Cable Lugs in Various Sizes

You can get Rayphen cable lugs having a large barrel and head or you can get it of smaller size.

Likewise, the diameter also increases or decreases according to the diameter of the cable you are attaching to it.

Q19. What is the Difference Between Cable Lug and Bimetal Lug?

Bimetal Cable Lugs                                                           Figure 12 Different Types of Bimetal Lugs

The bimetal lug is nothing different from the standard cable lug.

It is one of the types of cable lug.

Cable lug is a large term having smaller categories in it such as aluminum lugs, copper lugs, and bimetal lugs.

Copper and aluminum are made of single manufacturing material.

On the contrary, the bimetal lug has a barrel of aluminum and a head/palm of copper.

It can also be like this; copper barrel and aluminum palm/head.

Q20. What are the Features of a Low Voltage Aluminum Cable Lug?

The low voltage aluminum Rayphen cable lug is designed to get crimped on the conductors for terminal facilitation through the hole of the lug.

One type of aluminum cable lug contains shear bolts. It is known as a shear bolt lug.

Low voltage cable lugs have a moisture block at the joint of the barrel and palm of the lug.

It is manufactured for conductors conducting low voltages.

Q21. Why Use Medium Voltage Copper Cable Lugs?

It is preferable to use a medium voltage copper cable lug because of its key characteristics.

  • MV copper lugs do not have an inspection hold. It prevents moisture from ingress into the crimp.
  • They have an electroplated layering of the tin so as to make them oxidation resistant.
  • MV copper lug has a relatively long barrel for efficient electrical conductivity and mechanical strength.
  • It is appropriate for voltages up to 33kV.
  • These cable lugs are made under strict quality control standards.

Q22. Can You Replace a Cable Lug?

No, you cannot replace any type of cable lug once it gets crimped with the cable.

Crimping is kind of a permanent compression that does not allow the replacement of cable lugs.

Also, if somehow you are successful in getting the cable out of the crimped cable lug, it will not insert back into its barrel.

For that, you have to use a fresh Rayphen cable lug.

Q23. Can You Use Cable Lugs for Aerial Bundles Cables (ABC)?

No, you cannot use a cable lug for aerial bundled cables.

This is because aerial bundled cables are used in overhead connections and aerial lines.

The cable lug is not an overhead electrical fitting.

It can only connect two cables or any cable to some electrical appliance.

However, you can use a pre-insulated bimetal cable lug for such cables.

Q24. How to Check Whether Good Quality Cable Lug is Manufactured or Not?

The following are few points that will make you aware of good quality cable lugs.

  • The joint of barrel and palm is electromagnetically processed or friction welded.
  • It should be sturdy and robust.
  • The surface of the cable lug is smooth and without any bumps or burr.
  • It is made of pure aluminum or copper or both.
  • The dimensions are right as you asked for.
  • The product is gone through all quality control checks.

If the cable lug is fulfilling these points, it means it is a high-quality product.

Q25. Can You Get Waterproof Cable Lug?

Yes, you can get a waterproof cable lug.

The cable lugs have an oxide inhibitor filling that prevents corrosion from coming to the lug surface.

It also makes the barrel edges secure from humidity, oxygen particles, and dust.

Using a waterproof cable lug is safe as it gives safe electrical connections.

Q26. Are Cable Lugs Weather Resistant?

Yes, Rayphen cable lugs are weather resistant.

They are economical to use because of their resistance to harsh climatic conditions.

You can use them in aggressive environmental conditions.

Q27. How to Properly Pack a Cable Lug?

Proper packaging before delivery of cable lug is necessary.

It prevents shipping damages.

Plastic wrap the cable lugs and then put them carefully in cartons.

Again, wrap the boxes with plastic to completely seal them and prevent them from opening.

Make bundles of these cartons together and they are ready for shipment.

You can store them as you like; both outdoors or indoor setup.

Q28. How to Improve the Working Efficiency of Cable Lug?

The performance of the cable lug depends on the cleanliness of the barrel surface and inner edges.

Remember to clean it thoroughly before installation.

Clean the surface and edges of cables as well before joining.

Crimping it with an appropriate tool is also beneficial in enhancing the working efficiency of Rayphen cable lugs.

Q29. What Can You Do to Protect Cable Lug from Damages?

The manufacturing material of Rayphen cable lugs is very reliable.

There are rare chances of any damages but if proper crimping is not done, it might get damaged during the crimping process.

Look for the correct amperage and any current leakage prior to using a cable lug.

Q30. Is There Any Alternative Accessory to Cable Lug?

Yes, instead of using a cable lug you can use a shear bolt connector or mechanical corrector.

Both of these have a barrel and there are some cable lugs that come with bolts on their barrel.

Both of them serve the same purpose.

Cable lugs need crimping whereas shear bolt connectors do not necessarily need crimping.

Shear Bolt Connector                                                                Figure 13 Shear Bolt Connector

Q31. What Precautions to Consider While Making Cable Connections to Cable Lugs?

These are some precautions to keep in mind while making connections.

  • Use the appropriate size of cable lug that matches the diameter of the cable.
  • Read the user manual and apply the mentioned voltage before using the cable lug.
  • Using a metal cable lug with written crimping values is wise.
  • The crimping should be perfect; not over crimping and not under crimping.
  • You must use tested cable lugs against sort circuiting.
  • The barrel material and the cable material must be the same.
  • It is necessary to switch off the electricity before installing a cable lug.

Q32. Can You Use Cable Lug for ADSS Cables?

No, but you can use pre-insulated cable lugs for ADSS cables.

Again, the ADSS cables are on overhead connections and you cannot use a simple cable lug for that purpose especially high voltage.

Rayphen cable lugs are meant for secure cable connections together or with other devices.

It is not suitable to use them for aerial lines.

Q33. Can You Use Cable Lug for Earthing Wires?

Yes, you can use a copper cable lug or aluminum cable lug, or a bimetal lug for grounding wires.

Since the grounding wire is also made of such materials, it means cable lugs are highly compatible with them.

Crimp it with appropriate force through a proper tool and you are good to go.

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