Why Rayphen Copper Lug

Rayphen Copper Lugs

Rayphen copper lugs are designed to connect wires to an automotive battery as are the ends of battery jumper cables.

With Rayphen copper lugs, you can easily remove and install them for maintenance or repair. You can use Rayphen copper lugs permanently. However, the direct-fastening method is not necessary or feasible.

To avoid damage, shocks, and prevent short-circuit to your cables, connectors, and copper lugs, Rayphen designed copper lugs with safety covering and protective covering. You are assured that you can get a Rayphen copper lug with 100% guaranteed safe.

Our Rayphen copper lugs are manufactured for large gauge applications. So, you can definitely use it for grounding or power draw.

Rayphen copper lugs can be either soldered or crimped to the wire. You can get aesthetically pleasing finish Rayphen copper lugs as it features a burr-free appearance.

Plus, our copper lugs accommodate the cable using a welding, crimping method, or soldering, depending on your lug type.

Also, the other end of our copper lug is fastened to a matching connection point or terminal using a screw, bolt, or spring clip.

Rayphen is a leading electrical component manufacturer that offers an excellent quality copper lug for more than 14 years.

We are equipped with a state-of-the-art manufacturing facility. Our range of copper lug is manufactured in compliance with various international standards.

We can offer these crimping-type copper lugs tailor-made as per your requirement.

Aside from copper lugs, we are also experts in manufacturing overhead line fittings, compression sleeves, substation connectors, and many more.

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

If you want more details about our copper lugs, you can email us directly!

COPPER LUG: ULTIMATE FAQ GUIDE

Electrical devices like cables or conductors perform better and last longer with copper lug. This FAQ guide contains important information on the copper lug. It also serves as the right guide to picking the appropriate lug for your project.

Q1. What is Copper Lug?

                                                Figure 1 Copper Lug

A copper lug, otherwise known as a copper cable lug, is an electrical tool for connecting the wire to electrical gadgets, including other cables, devices, and mechanisms. A great example of a copper lug is clamped connecting wires to an automotive battery. As a matter of fact, the fasteners are the ends of jumper wires.

The installation process is worthy of discussion. On the shelves today, most copper lugs are designed with an easy installation process. Users have no difficulty in setting up the device for use. Also, copper lugs are effortless to maintain and repair when need be.

Generally, these electrical devices are used when the static and direct-fastening methods are unnecessary. Since there is a significant risk involved, users need to provide copper lug with safety covering to prevent shocks or damage to the tool. In fact, it is necessary to avoid short-circuit.

Any device perfect for a vast display application is known as a copper lug. Depending on your choice, copper lugs can either be soldered or crimped to electrical cables. On the other hand, a bolt or screw can connect the copper lug to the battery. Copper lug has a low coefficient of thermal expansion, and this reduces the risk of fire.

Q2. What is Copper lug used for?

                                                        Figure 2 Use of Copper Lug 

Copper lug is used in the electrical system to connect cables to electrical appliances. It is used to distribute electrical current between two or more electrical wires. As a matter of fact, they are perfect for high voltage electrical connection purposes. Copper lugs are used on both electronic devices and power cable systems.

Aside from this, manufacturers design copper lugs to connect fuse sockets, power circuits, electrical gadgets, and switches. With the copper material, it ensures adequate safe handling. You can quickly repair and use the electrical tool.

More often than not, one end of the copper cable lug is for cable connection to an electrical tool. This is usually through the welding or crimping method. On the other hand, the second end of the device is joined for connecting terminals of the electrical appliances. However, copper lug comes in different sizes and shapes. The type of copper lug you use depends on the kind of wires for connection.

Copper Lugs are widely used in power distribution cabinets, power distribution boxes, shipyards, and mechanical equipment factories. Other than all that, it is also applicable to factory equipment, distribution boxes, electrical equipment factories, household appliances. As a matter of fact, it is also used in production and processing facilities, metal processing and production industries, machine room line, and many more.

Q3. How to install a Copper lug?

                                                              Figure 3 Installing Copper Lug

Installing a copper cable lug is easy as long as you follow the installation processes. You don’t have to be an expert with the tool before you can get this done. To kick-off, select the copper lug type compatible with the electrical cables. Make sure you take safety precautions in order to prevent shock and power circuits.

Once you are protected, clip the wire to the length of the copper lug to fit in well. But, carefully strip the wire to prevent cutting the wire conductors. Select your installation device, set the wire in a proper position on the log, and hold the lug.

Meanwhile, the copper lug installation tool always features an excellent grip for easy handling. All you need to do is to hold the instrument, fix it in the copper lug, and put the trimmed wire inside the hole. After this, ensure you control the installation devices properly and press on the lug for easy connection.

Q4. What are Copper Lugs made of?

Copper lugs are mechanical lugs made from high-quality pure copper materials. The material allows for high temperature and electrical conductivity. Also, it is perfect for high-voltage connections. Consequently, in most wiring systems, copper materials are regarded as the best for electrical conductors. Nevertheless, it is used across the globe.

The main body of the copper lug is made of copper materials of a significantly high level of performance. One big draw of electrical devices made from copper is that they are budget-friendly and affordable. And this copper lug is not left out, and it is an alternative to all other expensive lug made from different materials.

Copper materials are generally corrosion-resistant. It is a material designed to withstand any hazard. Also, it is a good conductor for any heating application area. If you need a lug that can be easily repaired, then a copper lug is an option for you. Aside from the fact that it is recyclable, it is also easy to use and set up.

The copper lug has a lightweight design and a long-lasting feature. With its adaptability status, you can easily bend and shape the copper lug to your taste.

Q5. How to make Copper Lugs?

Users can effortlessly make a high-quality copper lug out of copper tubing or copper rod. Ensure you have a roll of copper tube. It is necessary to note that the pipe you get depends on the size or the electrical cables. For instance, if you are using a two gauge cable, you should get a complete 3/8 copper tube. However, below is the production process of the copper lug.

Cutting and Punching

To start, cut the copper cables and trim to the length of the lug. Study the line carefully and proceed to cut the copper tube with the cutting devices. Ensure to measure and mount both ends of the available copper tube. After the wires are cut, punch the end of the copper tube to make the holes on flat materials.

Annealing

After trimming the wire and punching the copper tube, comes the annealing process. This process increases the flexibility and softness of the copper tube. With this process, you can easily bend and shape the line without breaking down.

All you need to do is heat the already punched flat end of the pipe materials. Place the hardened copper line on concrete to prevent the tube from catching fire during the annealing process.

Use an annealing furnace with a small flame. With this, the annealing process produces high temperatures making the hardened copper product soft and better for use. Other than that, you can press the copper lug with force.

Stretching

Stretching the copper tubes is next after softening them. Users can either use the swaging or flaring tool to extend the flat end of the copper tubing. Moreover, this is to make the lug fit for the wire insertion.  This process is carefully done to prevent damaging the copper pipe.

Lache round and Forging

This is where the holes made during all the stretching of the heated copper tube are filled. It is done for the copper wire to fit in perfectly well. On the other hand, forging is the manufacturing process where the copper tube is reshaped to the desired shape of the lug.

The whole process involves hammering, rolling as well as pressing the tube. Although the process might lead to minimum waste of the properties, it increases the strength and performance of the copper lug.

Surface treatment

This process is to enhances the mechanical properties and gives an attractive appearance to the lug. This involves chemical treatment and all other treatment necessary, including acid cleaning or tin-plated. Fortunately, it is to increase the corrosion resistance of the already fabricated copper lug. With this, the copper lug can withstand moisture in any harsh environment.

Inspection package

The inspection package is the final stage of the copper lug manufacturing process. The copper lug is thoroughly checked for any fault or adjustment and then assembled and accredited for use.

Q6. Can we use Copper Lug with Aluminum Cable?

No! Copper Lug cannot be used with aluminum cables because of the differences in conductivity. Users should use aluminum lugs to terminate aluminum conductors. For termination of a copper conductor, you can either use the aluminum or the copper lug.

Over the years, electrical professionals tested and proven that using the aluminum-bodied lug with the copper cables is a successful process. On the other hand, the use of copper lugs to terminate the aluminum wires at any point in time failed. Using copper lugs with aluminum cables will always create a problem and increase the risk of damage. Meanwhile, to be free from any difficulties, use the perfect parameters for the copper lug.

What’s more? Copper lug is a safe and reliable device employed by most electrical industries. It is an electrical connection tool ideal for short circuits and resistance to wear. So, using an aluminum wire with the lug will increase the risk of exposure to humidity. More importantly, it can result in the breaking down of the copper lug.

Q7. What are Copper Lug Sizes?

                                                           Figure 4 Sizes of Copper Lug

On the market today, we have different copper lug shapes and sizes for supply. Generally, copper terminal lugs range from 1.5mm2 to 1000mm2. Nevertheless, some copper-bodied lug sizes include large cable sizes from 10mm2 to 240mm2 in varieties of stud sizes. These cable lugs come in sizes perfect from 6 AWG to 4/0 AWG. For instance, eyelet sizes are made available from ½”, ¼, “3/8, and 5/16. The kind of copper lug you purchase depends on the size of the copper wires.

As a matter of fact, other copper cable lug sizes range from 6 sq Mm to 630 Sq Mm. For bolted copper lugs, the measures are from 16 mm2 to 250mm2. A copper crimp lugs for terminating 120sqmm conductors 600/1000v is ideal with stud hole sizes of M8, M10, M12, M14, M16, and M20. In addition to this, each copper lug comes in different sizes and is used with different stud hole sizes.

Q8. Can I use Copper Lugs with Transformers?

                                                         Figure 5 Copper Transformer Lug

Yes! Copper lugs are perfect connection devices for transformers. This lug is essential for connecting cables to the transformer terminals. Many technicians use copper lug with a transformer to maintain electrical conductivity. Also, it is used to improve the mechanical strength of the cables. The Copper lug allows the transformer to withstand any form of vibration.

Copper lugs are not only compatible with the transformer, but they are also perfect with all other electrical segments. This includes motors, distribution board, generator, batteries, and many more. Lugs are used for terminating conductors with critical quivering. Whether a contractor is setting up or servicing the devices, the copper lugs keep the technicians safe from fire or any motion injury.

Also, all copper lugs are suitable for terminating copper cables for transformer high power voltage. Meanwhile, many transformers available on the shelves do not come with a clod. However, it is sold separately. To install a lug, you need to get the perfect one for the size and specification of the cables. Large transformers can be connected to a single large wire with a single copper lug. On the flip side, multiple conductors can be used with numerous copper lugs on a single terminal on the transformer.

Next, ensure the conductor is thoroughly cleaned to ensure no debris stays on the cables. Then use the installation devices to mount and tighten the lug on the electrical wires.

Q9. Is it better to Solder or Crimp Copper Lugs?

                                                    Figure 6 Crimping vs Soldering Copper lug

Getting to install a copper lug through the soldering method or the crimping method depends on the user’s taste. Both ways offer unique connection features depending on the electrical cable types. Copper can either be crimped with a cable lug crimper or hammer-style crimper. In another sense, the soldering method involves the use of solder lugs or other electrical solders.

In most electrical systems, crimping copper lugs is much better than soldering them. This is because the crimping method is effortless to use and maintain. Crimpings offer reliable connections than using the soldering method. Welding requires a cable with a connector, unlike soldering that requires joining electrical wires with heated metal.  Meanwhile, the heated metal can degrade over time, affecting the cables connections

What makes the crimping method ahead of soldering is its protection features. Crimping copper lug protects the cables from the intrusion of moisture and any form of debris. Unfortunately, the soldering copper lug does not provide the same level of protection.

Q10. How to crimp Copper Lugs?

                                                          Figure 7 Crimping Tool

When you are crimping or welding copper lugs, connect the lugs to the cables well for high power productivity. To start with, get your crimping tool, either cable lug crimper or hammer-style crimper.

To get the connectivity you want, trim the wire to the length of the available copper lug. Ensure the exposed conductor is free from any particles. Then, use your knife to slope the end of the lug slightly. Ensure the wire fits in the copper lug ideally. Check thoroughly for easy connections and installation.

To crimp the lug, put the already fix copper lug inside the crimping tool. Carefully apply pressure on the lug with the crimping tool to avoid getting the lug damaged. With this, you have successfully crimped the copper lug and hold the cables for lifetime use.

Q11. Differences Between Tinned Copper Lug and Bare Copper Lug?

                                                              Figure 8 Tinned Copper Lug

                                                            Figure 9 Bare Copper Lug

One big difference between the tinned copper lug and bare copper lug is the capacity to resist corrosion. In this field, the tinned copper lug is more resistant to corrosion than the bare copper lug, which is fairly corrosion-resistant. As a result, the tinned copper lug stays long, irrespective of the weather. For instance, bare copper lug damages quickly in high humidity environments or wet areas. In these locations, tinned copper lug works efficiently and effectively. It protects your conductor, wire, or electrical device from oxidation or any harmful substance.

If you are to consider the price, bare copper is affordable. Technicians who need a budget-friendly cable protector would definitely have the bare copper lug in their book. A tinned copper lug is an excellent device for contractors who want to invest in a durable and safe copper lug.

Material construction is another major feature that separates tinned copper lug from its bare copper counterpart. Both copper lugs have a solid and durable coating. However, the tinned copper connector lasts longer than the bare copper lug. It works for an extended period, whether the environment is wet or dry.

There is also a slight difference between the tinned and bare copper lug for installation. Unlike the latter, the former is simple to connect. With its solder primary component, the tinned copper lug is ideal for wet environments, high temperatures, and high humidity.

The bare copper lug has better conductivity performance than the tinned copper lug. It is also ideal for a conductor or electrical device with high voltage.

Q12. Can I use Pure Copper wire with Tinned Copper Lugs?

                                                                         Figure 10 Pure Copper Wires

It is okay to use pure copper wire alongside tinned copper lugs. In contrast to some opinions, tinning copper lugs doesn’t reduce the pure copper wire’s efficiency and effectiveness. Rather it eliminates oxidization that makes the wireless efficient. One big draw of the copper lug is its powerful insulation. The insulation makes the conductor immune to corrosion or any toxic and harmful material.

It would be best to use pure copper wire with tinned copper lugs, especially in areas where your wire is exposed to long-term water. Often, saltwater weakens and reduces the copper conductor performance. So, the only way to preserve the wire’s efficiency is by installing tinning copper lugs.

Another reason a tinned copper lug is ideal for pure copper wire is durability. Without any debate, tinned copper lug extends the life of the pure copper conductor. It also keeps technicians safe from electrical hazards.

Like bare copper, the tinned copper lug has high conductivity performance. So, if you are looking to buy a lug with corrosion-resistant features as well as reliable conductivity performance, look no further than tinned copper lugs. Don’t forget these copper protectors are also simple to solder. Therefore, you would have no trouble installing or using them with any pure copper wire.

Q13. How to Select a Copper Lug?

Selecting an appropriate copper lug might not be as simple as you think. Like other electrical devices on the market today, copper lugs are available in hundreds of thousands of models. Therefore, it is tricky choosing the right lug for the electrical device. Here are essential features and factors that help you make the right decision.

Conductor Class

The conductor class is one of the essential factors to consider when choosing a copper lug. According to DIN EN 60228, there are different copper lugs ideal for varying cables. For instance, compression copper lugs are perfect for conductor classes 1,2, 5, and 6, according to DIN 46235.

On the other hand, standard type tabular copper lugs are the appropriate conductor lugs for conductor class 2. Also, it is safe and effective to use solderless terminals with conductor classes 2,5, and 5, according to DIN 46234.

Irrespective of the conductor class or lug kind, it is safe to use crimping tools with coded dies while crimping conductors. As a matter of fact, using these tools keeps all technicians safe.

In a nutshell, it is important to install the right copper lug on the appropriate conductor class. You can contact your contractors if you have little or no idea of the conductor classes.

Installation

Many technicians use copper lugs owing to their simple installation processes. So, if you are picking an electrical lug to connect two separate electrical devices, you need to consider the mounting process. You should go for copper lugs with easy and fast installation procedures. Besides saving you time, the device also saves you extra bucks you would have spent hiring third-party contractors.

There are two significant copper lug installation methods. As stated earlier, both methods are simple and quick to execute. So, the option you select depends on your preference. Besides, the tools to execute each installation method differ.

Environment

Considering the environment of installation is as important as any other condition. There are copper lugs that perform pretty well irrespective of the location. Others deliver in the right location. Therefore, you need to be aware of the lug’s ability and the ideal environment.

For instance, a tinned copper lug is a device perfect for all-weather or location. Its insulation feature enhances its performance no matter the terrain. It is also corrosion-resistant and keeps oxidization away from the conductor or cable.

On the other hand, the bare copper lug isn’t as versatile as its counterpart. In fact, it is less efficient in high humidity areas or wet environments. Also, using the right copper lug in the best location assures its effectiveness and contractor’s safety.

Manufacturer

Our list of the factors to consider when picking the right copper lug is incomplete without this condition. You might find this addition weird, but considering the manufacturer is also as vital as any other factor. On the market today, there are numerous copper lug’ producers. While there are brands that have made their mark in this field, others develop with little or no recommendation.

Therefore, it would be better if you choose products from renowned companies. One big draw for doing so is the guarantee. Rather the profit, popular manufacturers are much more interested in satisfaction. So, they ensure the product delivers what you want.

In the electrical world today, we are one of the reliable and high-quality copper lug manufacturers. Our products are of superior quality, and they deliver exactly what you want in the way you want it. There are unlimited copper lugs you can check from Rayphen!

Q14. Why is Copper Lug?

Copper lugs are important for attaching electrical devices, mechanisms, or cables to other cables. Hardly can you achieve a proper connection between these devices without a copper lug.

Whether for power draw or grounding, you would find copper lug useful in large gauge applications. Likewise, copper lugs are also the favorite connector in power or electrical applications. One of the many benefits you would enjoy using a copper lug is the corrosion-resistant feature.

This feature prevents the wire or conductor from damages or oxidation. It also provides it with extra protection against corrosion.

If you want your wire, cable, or conductor to last longer, it would be better to purchase a copper lug for connection. Unlike other connectors, copper lugs are simple and quick to set up. You can either choose to install it via soldering or crimping. Irrespective of your preferred method, mounting the copper lug is a piece of cake.

Another feature that keeps the copper lug ahead is its simple repair and maintenance feature. Unlike other devices that are only installed permanently, copper lugs are better options. These lugs are designed for easy removal whenever you need to clean or repair them.

Q15. Copper lug vs. Aluminum lug?

                                                            Figure 11 Copper Lugs  vs. Aluminum Lugs

Mechanical lugs have two major material coatings. These constructions include copper and aluminum material. Many contractors find it a bit difficult picking between these two lugs. If you are one of them, we got something big for you in this part.

Having difficulties choosing between copper and aluminum lugs isn’t a flaw. Rather, it is a result of the similarities in the features. So which one do you pick?

Before going in-depth into how to pick between the two lugs, it is important to know that both perform similar functions. However, the design feature or benefits vary. One thing you should know about aluminum lug is its existence from the ancient period.

As of 1960, it was a popular connecting device in many homes in the US. However, the history of the device took a U-turn when the contractors ran to termination failures. For aluminum lugs, this was a Waterloo. For copper lugs, it is a stepping stone.

Picking between these two lugs depends on so many factors. For budget, aluminum is budget-friendly, while copper is a bit costly. However, aluminum connectors cause many problems. Many contractors consider it less efficient than copper lug.

Another difference between both electrical lugs is corrosion resistance. This, copper lug stay ahead of the aluminum lug. Irrespective of the environment, the copper lug is resistant to moisture, dirt, debris, and corrosion, unlike the aluminum lug.

The aluminum lug is compatible with aluminum wires with different parameters. On the flip side, a Copper lug is perfect for copper cables or wires. What’s more? Many contractors are ready to invest in the safer and reliable copper lug. But this doesn’t make the aluminum lug unsafe.

As a matter of fact, new developments make the aluminum device as safe and strong as the copper counterpart. Even though there is regular aluminum electrical wiring and components’ improvement, many still consider the copper lug better because of what it has to offer.

Q16. How long does Copper Lug last?

Copper materials are materials that are made to last for an extended period. Since you don’t want to spend pretty much on repairing your lug, a lug made with copper materials is an option for you. Copper lugs are built with the interest of users in mind. Its durability feature is second to none. So, you can have it for as long as you want.

Generally, copper materials do not deteriorate at any point in time. Copper Cable lugs are constructed to withstand any form of deformity and resistance to corrosion. Irrespective of the application areas, it holds the wire well and has low power consumption. As long as you use the perfect Copper bodied lug with the appropriate Copper cables, be sure it will last you for longer or a lifetime.

Q17. What is the Safety Caution of Copper Lug?

Copper Lug can provide an unpleasant smell when exposed to heat or flames. More often than not, this inhalation of fire may lead to irritation and affect an individual’s health. So before making use of the lug, cover your nose to safeguard you from convulsing as a result of fire or explosion hazards.

Also, put on protective clothing to prevent you from direct skin contact. And wear safety gloves to prevent you from shock. That’s not all! Ensure you have protective glasses on to protect your eyes from fume, dirt, or any form of debris. To protect your feet, make use of safety boots. However, copper lugs should not be exposed to any water. Users can use damp cloths to clean the lug when need be.