C45 Insert-in Copper Lug

Ensuring reliable and safe electrical connections is fundamental in modern electrical systems, especially within control panels and distribution boards. While screw terminals and clamp-style terminal blocks offer convenient connection points, terminating fine-stranded copper conductors directly into them can present challenges like stray strands, insufficient contact area, and potential loosening over time. VIOX addresses this challenge with the specialized C45 Insert-in Lug, a type of non-insulated, pin-shaped crimp terminal engineered specifically to provide a clean, solid, and reliable interface between stranded wires and clamp-style terminal blocks, particularly those conforming to C45 standards or similar designs.

Often referred to as a C45 pin terminal or cord end terminal, this component acts as a crucial intermediary. It converts the flexible end of a stranded wire into a solid, dimensionally consistent pin, perfectly suited for insertion into terminal blocks designed for solid conductors or pins. This product, though sometimes categorized under the broad term copper lug, serves a distinct function compared to traditional ring or fork lugs which connect to studs or screws.

Understanding the C45 Insert-in Lug Design

The unique design of the VIOX C45 Insert-in Lug is purpose-driven:

• “C45” Designation: This commonly relates to compatibility with C45 DIN rail terminal blocks, circuit breakers, and other components that utilize specific insertion slots or clamping mechanisms. Using a C45-designated pin ensures dimensional compatibility for a secure fit.
• “Insert-in” Functionality: The solid pin end is designed to be directly inserted into the receiving clamp of a terminal block (screw clamp, spring clamp, etc.).
• “Pin-Shape”: The termination end is a solid, often flattened pin, providing a defined contact surface area that interfaces reliably with the terminal block’s clamp.
• “Non-insulated”: These terminals are supplied without plastic insulation sleeves, making them suitable for use within enclosed panels or where insulation requirements are met by the terminal block itself or overall system design.
• “Crimp Terminal”: The rear section features a seamless barrel designed to be permanently crimped onto the stripped end of a stranded copper wire, creating a strong mechanical and electrical bond.
• “Copper Tinned”: Manufactured from high-conductivity copper (specifically T2 grade copper noted in specifications) and finished with electro-tin plating, ensuring excellent current carrying capacity, durability, and long-term resistance to corrosion.

Engineering Advantages and Benefits

Utilizing the VIOX C45 copper pin terminal offers significant advantages in electrical assembly and system reliability:

• Eliminates Stray Strands: Securely contains all conductor strands within the crimp barrel, preventing stray strands that could cause short circuits between adjacent terminals.
• Ensures Reliable Contact: The solid pin provides a consistent, defined contact surface area within the terminal block clamp, leading to lower contact resistance and reduced risk of overheating compared to improperly terminated stranded wire.
• Simplifies Installation: Allows for quick and easy insertion of stranded wires into terminal blocks, similar to using solid wire, speeding up assembly time.
• Enhances Connection Security: The solid pin provides a stable conductor form for the terminal block clamp to grip, reducing the chance of loosening due to vibration or thermal cycling.
• Improves Durability: The tin-plated copper construction resists corrosion and ensures a long service life. The seamless barrel provides a robust crimp connection.
• Facilitates Maintenance: Wires terminated with pin lugs can be easily removed and reinserted into terminal blocks during maintenance or system modifications.

Typical Applications for C45 Insert-in Lugs

The unique characteristics of the C45 non-insulated cord terminal make it indispensable in various applications, including:

• Control Cabinets and Panel Building
• DIN Rail Mounted Terminal Block Assemblies (especially C45 types)
• Circuit Breaker and Contactor Wiring
• PLC (Programmable Logic Controller) I/O Wiring
• Industrial Automation and Machinery
• Power Distribution Units
• Anywhere stranded conductors need reliable connection to clamp-style terminals.

Technical Specifications: C45 (A) & C45 (B) Series

VIOX offers the C45 Insert-in Lugs in various sizes, potentially grouped into types like C45 (A) and C45 (B), which may differ slightly in dimensions or wire range suitability. Please refer to the tables below for detailed specifications:

C45 (A) Insert-in Lug (tube)

C45 (B) Insert-in Lug (tube)

Table Legend (referencing diagram): D: Barrel Outer Diameter; d: Conductor Entry Inner Diameter; L: Overall Length; L1: Pin Length; B: Pin Width; Wall thickness: Barrel Material Thickness. Models (e.g., C45-16ᵀ) typically indicate the nominal conductor cross-section in $mm^2$ the terminal is designed for. Note the distinct dimensions between C45(A) and C45(B) series for potentially overlapping wire sizes.

C43 Insert-in Lug Dimension

Installation Recommendations

Achieving a secure and reliable connection with a C45 insert lug requires proper installation:

1. Wire Stripping: Strip the wire insulation to the correct length, exposing enough conductor to fully insert into the crimp barrel without excessive bare wire showing after crimping. Avoid nicking conductor strands.
2. Crimping Tool and Die Selection: Use a high-quality crimping tool designed specifically for pin terminals or cord end ferrules. Select the correct die nest size matching the C45 lug being used. Using incorrect tools (like those for standard ring lugs) can result in a poor crimp.
3. Crimping Procedure: Insert the stripped wire fully into the lug barrel. Place the barrel into the correct die nest and complete the crimp cycle according to the tool manufacturer’s instructions. Ensure a firm, uniform crimp is achieved.
4. Terminal Block Insertion: Open the clamp on the terminal block. Insert the crimped C45 pin fully into the terminal opening until it bottoms out or reaches the appropriate seating depth.
5. Secure Clamp: Tighten the terminal block screw or engage the spring clamp securely onto the inserted pin. Verify the connection is mechanically secure.

Trust VIOX for Quality C45 Pin Terminals

VIOX is committed to providing high-quality, reliable electrical components. Our C45 Insert-in Copper Lugs are manufactured using high-grade T2 copper and precise processes to ensure dimensional accuracy and consistent performance. With VIOX C45 terminals, you can build electrical panels and systems with confidence, knowing your stranded wire connections are secure and built to last.

Need reliable pin terminals for your next project? Contact VIOX today to inquire about our C45 Insert-in Lugs, request samples, get a quote, or discuss which C45 type (A or B) best suits your specific application requirements.