Why Rayphen Bimetal Lug

Rayphen Bimetal Lug

Rayphen bimetal lugs manufacturer in China produced bimetallic cable lugs with great advantages. All of our bimetallic lugs are guaranteed safe and low cost both in and use.

Also, we can fabricate electro-tinned to IEC61238-1 DIN 46329 standard bimetal lugs. So, it can prevent from oxidation and corrosion.

Another advantage of Rayphen bimetal lugs is the smooth surface, To avoid bruising when bimetal lug acid cleaning. At Rayphen, We can supply you bi metal lug beauty and good electrical contact performance.

Plus, the entry to the wire barrel is chamfering and high concentricity for easier and faster conductor entry and they are shock-proof.

Rayphen has a full range of bimetal lug for both named conductors and standard metric conductors. As a leading manufacturer, all of our bimetal lug is fabricated with very strong friction welded AL/CU joint, to ensure bimetallic lug weld strength.

We also fabricate custom bimetal lug based on your specifications and wishes. Rayphen bi metal lugs are rigorously tested and complete with identification for reliability.

Aside from bimetal lug, we also offer copper lugs, overhead lines fittings, line hardware fittings, compression sleeves, electrical substation line, and many more.

Whether you are a bimetal lug supplier, distributor, or custom factory, Rayphen is always the best choice!

Please don’t hesitate to contact us for more details.

Bimetal Lug FAQs-The Ultimate Guide

In this article, complete details about the bimetal lug will be discussed to give you a complete understanding of this product.

There are frequently asked questions about the usage, material, and other international manufacturing standards for the bimetal lugs. All the answers are briefly explained and images and diagrams are used where required.

Q1. What are Bimetal Lugs? 

Bimetal lug is a kind of terminal that is used at the edge of cable for joint or termination of cable. Bimetal lug has two different parts; barrel and palm and these parts are made with two different metals.

The lugs are also used for a connection between cable and any device or equipment.

Q2. What are the types of Cable Lugs?

There are main three types of electrical lugs; copper lug, aluminum lug, and bimetallic lug. Each type of lug can be used for a different purpose at different places.

Q3. What are Bimetal Lugs made of?

As showing from its name, bimetal lugs are made with two different materials. Its barrel is made with different materials and palm with different, and these two parts are welded by making a durable joint.

The lug can be made with an aluminum barrel and copper palm or copper barrel and aluminum palm.

Copper cable is used in the copper barrel and aluminum cable is used in the aluminum barrel. A specific grease is applied to its internal surface which helps to protect it against oxidation.

The barrel end is also covered by a cap to protect it against dust etc.

Q4. What are international standards in manufacturing of Bimetal Lug?

Some international standards are to be followed while manufacturing the bimetal lugs. Below is the list of those standards:

• IEC 61238-1 – Mechanical and compression for power cables. Rating: voltages up to 30 kV (Um = 36 kV). Part one: Test methods & requirements
• IEC 60228 – Insulated cable conductors
• EN 12449 – Copper and copper alloys. Round tubes and seamless for general purpose
• EN 13599 – Copper plate, strip, and sheet with copper and copper alloys for electrical purposes (DIN 48201)
• EN 13600 – Copper alloys and copper. Copper tubes (seamless) used for the electrical purpose (DIN 40500 part 2)
• EN 14121 – Aluminum alloys and aluminum, aluminum sheet, plate, and strip used for electromechanical applications (DIN 40501)
• EN 50483-4 – Test requirements for aerial bundled cable accessories which have low voltages – Part 4: Connectors
• DIN 46329 – Ring type cable lugs used for compression connections and aluminum conductors
• DIN 46239 – Compression cable lugs & connectors made with aluminum
• NFC 33 090-1 – Compression connectors used for insulated cables – part 1: volume compression of aluminum conductors (deep stepped indent controlled)
• NFC 33-021 – Insulated cables with their accessories used for power systems – connecting equipment (like pre-insulated compression) for overhead services and distributions with bundle assembled cores. Rating: voltage 0,6/1 KV 

Q5. Are Bimetal Lugs durable?

Bimetal lugs are made with hard material (i.e. aluminum and copper). So, these lugs are much durable. The joint where its two parts (barrel and palm) are merged, is friction-welded. It creates a better transition between barrel and palm and makes the whole lug durable.

Q6. How to install the Bimetal Lug?

You can follow the below steps to understand the installation of the bimetal lug.

1. Strip the cable:

First of all, strip the cable with the proper tool to insert it into the bimetal lug’s barrel. Remove its sheath and separator tape carefully from the conductor.

                                                                                   Stripping the Cable

2. Remove oxide:

Copper and aluminum cables are covered with an outer layer, which is known as the oxide layer. Remove that oxide layer carefully. The oxide layer on the copper cable is softer as compared to the aluminum cable.

3. Apply an oxide breaker:

Now you have to apply a specific oxide breaker paste on both the conductor and surface of the barrel of the bimetal lug. It prevents the formation of oxide and decreases contact resistance.

                                                                          Applying Oxide Breaker

4. Insert the cable and crimp the lug:

Insert the cable carefully within the barrel of a bimetal lug. Use an appropriate crimping tool as per the relevant size of the bimetal lug. And crimp the barrel to fix the cable tightly with the bimetal lug.

                                                                     Crimping the Bimetal Lug

5. Apply a heat shrink sleeve:

And in last, apply a heat shrink sleeve after crimping the bimetal lug. This heat shrink sleeve creates a seal and prevents the back of the lug from dust or ingress.

Applying a heat shrink sleeve

Q7. How do you crimp Bimetal Lugs?

Crimping is the most important part of the installation process of a bimetal lug. There are multiple ways to crimp your bimetal lug. You can crimp it by using a screwdriver and hammer for small bimetal lugs.

But it is suggested to use a proper crimping tool to crimp it for durability and strong connection. The crimping method is very simple.

1. First of all, choose the correct bimetal lug size according to the cable size. Big sized lug will not fit on the wire properly.
2. Remove the insulation properly from the wire according to the length of the barrel of the bimetal lug
3. Then squeeze the bare cable a little bit, so that it can be inserted into the barrel properly
4. Use a proper crimping tool to crimp the bimetal lug (a hydraulic crimping tool can be the best option for some bimetal lugs)
5. You can crimp on two or three places of the barrel (according to the length of the barrel)

In case, if you think that the wire is a bit loose or not properly fit in the barrel, you can solder it to tight it properly.

Q8. Is Bimetal Lug waterproof?

Yes, bimetal lugs are waterproof. The internal surface of the barrel is anti-oxide and contact resistant.

Furthermore, a heat shrink sleeve is also applied. All these measures prevent the bimetal lug from ingress and make it waterproof.

Q9. Is Bimetal Lug weather resistant?

Bimetal lugs are highly weather and heat resistant. It is used in many outdoor places. Due to its hard material, it can survive in any kind of weather. These lugs can resist temperatures up to 120°C.

Q10. What is the weight of the Bimetal Lug?

The weight of a bimetal lug is different according to its type and capacity. The average weight of a bimetal lug ranges from 30 to 800 grams.

Q11. What are the technical requirements of a Bimetal Lug?

There are some technical requirements for the manufacturing of bimetal lugs.

• The palm and barrel should be friction welded or electromagnetic process. And the joint should be covered with a painted epoxy strip
• The aluminum used in the manufacturing should be E-A1 – F10 following DIN 40501
• The bimetal lugs should be appropriate for the installation of power cables conductors which are manufactured according to the standard IS 65 (IEC 60228) and fixed on the copper bar with M6, M8, M10, M12, or M16 screws.

Q12. How to test the Bimetal Lug?

As a buyer company, you can test the delivered bimetal lugs in several ways to make sure that it is the exact product that you have ordered.

• Verify the compliance of delivered bimetal lugs according to their specifications.
• You can partially or fully perform the acceptance test following IEC 61238-1 clause 6 “A” class and DIN 46246
• Make sure that each lug have valid COT & COA of the AL/CU
• Perform regular test for plating inspection and dimensional inspection

You can contact your supplier if any of the test(s) fail.

Q13. What is the quality check procedure for Bimetal Lug in the company?

Companies perform different quality checks following the international standards and regulations in the manufacturing of bimetal lug. Below are some major quality checks and tests performed by the manufacturers of bimetal lugs:

• Short circuit and heat cycle tests – BS EN 61238-1
• Chemical composition of copper and aluminum – BS EN 13600 and BS EN 754-1&2
• Friction stir welding – ISO 25239-1
• Dimensional checks to DIN 46329 and DIN 46235

Q14. What is the useful life of a Bimetal Lug?

You don’t have to worry about the useful life of a bimetal lug. These are long-lasting products. Once you have installed it properly and the bolt with a Belleville washer is torqued to specification, then you can leave it for a lifetime.

Unless it is not damaged with short-circuit. As these are made with aluminum and copper material, so there are no chances of rusting.

Q15. How does Bimetal Lug work?

Bimetal lug is a very useful terminal to connect the cable with any device or other cables. In the bimetal lug, its barrel can be made of aluminum or copper material.

So, the wire of the same material should be connected with the barrel (i.e. copper wire with the copper barrel and aluminum wire with the aluminum barrel). In this way, the same contact gives effective electric flow.

And there is a friction-welded joint between palm and barrel, which creates a strong connection between these two parts. The electric flow comes from the wire to the barrel of the bimetal lug, and then into the palm. That delivers it to the connected device or another lug.

Q16. Does Bimetal Lug come up with a warranty?

The different warranty period is provided by different companies. Normally, there is 12 months warranty period for a bimetal lug. In which, the company will replace the product if it was faulty or damaged when you received the delivery.

Q17. What are the inspection methods of Bimetal Lug?

As a buyer company, you can test the delivered bimetal lugs in several ways to make sure that it is the exact product that you have ordered. You can perform the following test to inspect the bimetal lugs:

• Appearance quality inspection
• Size inspection
• Mechanical test
• Short circuit test
• Heat cycle test

Q18. Can the Bimetal Lug be repaired?

No, this is not possible to repair the bimetal lug. Although these lugs are long-lasting and there are very few chances of their damage. In any case, if it is damaged, you can buy the new one.

Or if it was damaged or manufacturing fault at the time deliver, then you can straight away contact your supplier to replace the damaged bimetal lugs.

Q19. What are the different designs of bimetal lug?

Different types of lugs are used for different purposes.

Round Head Bimetal Lug:

Roundhead bimetal lugs are used on the nut and bolts area. As you can see in figure 5, the head of this lug is round shape.

                                                                 Round Head Bimetal Lug 

Square Head Bimetal Lug:

Squarehead bimetal lugs come up with single, double, or 4 holes on its palm. You can use them according to the usage and application requirements.

                                                                           Square Head Bimetal Lug

Pin Type Lug:

This type of lugs is used in terminal blocks.

                                                                    Pin Type Bimetal Lug

Q20. Where the Bimetal Lug is commonly used?

The bimetal lugs are commonly used in electrical devices and appliances.

Moreover, these lugs are used at industrial places, to make a wired connection with machines or other cables. Another common use of bimetal lugs is in automotive batteries or other devices.

Q21. What are the storage requirements of Bimetal Lugs?

There are no strict storage requirements for the bimetal lugs. The lug is not much sensitive electrical product. You can store them in both indoor and outdoor places.

Normally these lugs are shipped in wooden pallets for appropriate folk lifting. You just have to make sure that the weight of each pallet should not exceed 1250 kg while placement.

Q22. What kind of packing do you provide for Bimetal Lugs?

First of all the bimetal lugs are packed in plastic raping. Then these packets are put into the carton boxes.

Carton boxes are plastic wrapped with 6 to 12 carton boxes making a bundle. Then these bundles are shipped seaworthy wooden boxes and wooden pallets.

Q23. What is the usage of Lugs?

Electrical lugs are used where the permanent connection between different devices and other devices is not possible. Cable lugs help you to in the easy installation of different devices.

Its common usage is in repair and maintenance devices and tools, in which a temporary connection or circuit is formed to test the device.

In most places, electrical lugs are used to connect two different cables or connecting many cables with one cable. Lugs help to create a secure and durable joint or connection between them.

Q24. How to compare the quality of different Bimetal Lugs?

To choose the best quality bimetal lug from different lugs, you have to consider some important points in your mind.

• Its joint should be strong and sturdy with friction-welding (If it can pass the bending test)
• Its surface is smooth without burrs
• It is made with 99.5% aluminum purity and 99.9% copper purity
• The company gives you quality guarantee and they provide you sufficient return or change policy
• Whether the dimensions are as required, etc.

For more information, you can contact us

Q25. How to improve the performance of Bimetal Lug?

The bimetal lugs perform well if you clean them before installation. Clean the both cable and internal side of the barrel for its better performance.

Crimp it carefully and seal the end of the barrel to avoid dust and ingress. Keep the palm clean and protect it from dust or oil. This increases the performance of the bimetal lug.

Q26. How to protect the Bimetal Lug from damage?

The bimetal lug is made with a hard material. So, there are very few chances of its damage. Just be careful while crimping. Sometimes, it can be damaged or broken with inappropriate crimping.

Also, use the appropriate voltage according to its capacity. And be careful about the short circuit.

Q27. Which procedures are performed to avoid oxidation of copper?

The aluminum barrel and the cable are chemically treated. Later on, they are filled with corrosion inhabitants.

The conducive type paste or grease with a high dripping point is used for this purpose. This procedure helps to reduce the oxidation of copper.

Q28. Is there any alternative to Bimetal Lug?

Mechanical cable lug or mechanical connectors can work as a bimetal lug to an extent. There are also known as shear bolt lug and shear bolt connector.

There is no need to crimp these lugs and connectors. Instead, there are bolts on its barrel which tightens the cable inside it.

                                                 Shear Bolt Cable Lug and Connectors

Q29. What is the difference between Bimetallic and Mechanical Cable Lug?

Mechanical cable lug is also known as electrical cable lug. The main difference between bimetallic and mechanical cable lug is easier to install.

Because there is no need to crimp it. It has bolts on its barrel. So, you can easily tight them to fix the cable inside. On the other hand, the bimetallic lug needs a crimping tool to install it.

If we compare the cost, then mechanical lugs are more costly as compared to bimetallic lugs.

Bimetallic lugs are manufactured with two materials; aluminum and copper, while mechanical lugs are manufactured with aluminum alloy.

Q30. How to replace the Bimetal Lug?

Once you have installed the bimetal lug, then it is not possible to replace it. The reason behind this is that it is crimped while installation. So, this is not possible to remove the cable from the barrel.

Moreover, if the cable is removed anyway, it will not be possible to fix the wire again in the crimped barrel.

So, if the replacement is required, you have to use the new bimetal lug.

Q31. Can a Bimetal Lug be used for aluminum cable?

Yes, a bimetal lug can be used for aluminum cable. Bimetal lugs come up with two options, copper barrel and aluminum palm or aluminum barrel with copper palm.

So, you can use the bimetal lug with the aluminum barrel for aluminum cable. Because there should be the same material for cable and barrel.

Q32. What is the difference between a bimetal lug and copper lug?

There is a difference in the material in both lugs. The bimetal lug is made with two materials; aluminum and copper, while the copper lug is purely made with copper. And only copper cable is used with the copper lug.

The working, designs, and functions are the same for both of the lugs.

Q33. How do you choose the right Bimetal Lugs?

It is not always easy to choose the right bimetal lug from the wide variety. Choosing the right lug depends on the conductor as well. Connectors are electromechanical parts that interface electrical lines.

Accordingly, the electrical boundaries of the actual connector are the principal thought in choosing a connector.

The right choice and utilization of electrical connectors is a significant part of guaranteeing circuit dependability.

You should also match the temperature rating of the wire with the lug. Choose the correct lug according to the size of the cable. And crimp it appropriately with the correct crimping tool.

Q34. What are the features of Bimetal Lugs?

Bimetal lugs help to create an extremely reliable connection between two different conductors.

Friction-welded joint creates a high-quality connection between palm and barrel. The following figure explains its features in detail:

                                                            Features of Bimetal Lug

Q35. Why did Bimetal Lug fill with oxide grease (oxide inhibitor)?

The bimetal lugs are filled with oxide inhibitors to prevent the lugs from oxidation. Oxide inhibitor is specific grease that is processed through a chemical reaction.

It seals the lug (especially the barrel part) from any kind of humidity, dust, and oxygen.

Q36. What are the specifications of a Bimetallic Lug?

Bimetallic lugs are made with 99.5% aluminum and 99.9% copper. The electrolytic aluminum barrel is friction-welded with the electrolytic forged copper palm.

In this way, molecules of aluminum and copper create a strong bonding which creates a durable joint. Aluminum barrels are chemically treated and then filled with oxide inhabitant to prevent it from oxidation.

Q37. What are the precautions for cable connection with Bimetallic Lug?

There are few precautions to use the cable connection with bimetal lugs:

• Always use appropriate lug size according to the cable diameter
• Read the instructions and maximum voltage capacity on the bimetal lug carefully before its installation
• Use the bimetal lug with crimping signs on its barrel
• Do not over-crimp or under-crimp the cable and use a proper crimping tool
• Use the bimetal lug which is tested for short-circuit
• Always switch off the main electric line before installing the bimetal lug on live electric wire
• Use the same material of barrel as with the cable material

Q38. Can we use more than one Bimetal Lugs on one joint?

You can use more than one bimetal lug on a joint if various cables are required to connect at one point. For that purpose, you have to use the bimetal lug with the hole to connect it with other bimetal lugs with nut bolts.

It creates a durable connection to maintain flawless electrical flow in the circuit.

Q39. Is it possible to use Single-Metal Cable Lugs?

Yes, you can use single-metal cable lugs. Other than bimetal lugs, single-metal electrical lugs are available in the market, which can be aluminum lug or copper lug. But it is not always easy to choose between them. Each material has its specific usage and system requirements.

For example, if you have an aluminum wire circuit, then you have to choose the aluminum lug or vice versa. If we compare the cost of both materials, then aluminum is cheaper as compared to copper but it is not much secure.

So, it is recommended that always consult with the expert while choosing the right lug for your system.

Q40. Do you provide a QC check service for bulk orders?

Yes, the QC check procedure is performed in each order to maintain the 100% quality safety of the users.

All the finished products are audited and inspected by the expert of the company’s quality assurance department. The experts also make sure that the products are made following the relevant international and local standards and regulations.

Q41. Can Bimetal Lug be used at home?

The major use of bimetal lugs is at commercial places like grid stations, industrial places, construction sites, repairing labs, and units. However, these are used at a few appliances and circuits at a domestic level.

Q42. Can a Bimetal Lug be used for grounding wires?

Usually, the grounding conductor is copper. Copper lug is mostly used for grounding wires. And as you know that bimetal lug includes both aluminum and copper material. So, it can not be used in grounding wires frequently.

However, a bimetal lug can be used if it not makes a contact with earth or masonry. It is recommended that do not use the bimetal lug within 18 inches of earth.