DT Copper Lug

Welcome to VIOX’s comprehensive guide to our DT Copper Lug series, engineered for superior electrical connectivity across industrial, commercial, and residential applications. Crafted from high-purity electrolytic copper and designed with precision, our DT Copper Lugs deliver the perfect blend of conductivity, durability, and installation convenience for your most demanding electrical connections.

Superior Design and Construction

The DT Copper Lug represents the pinnacle of terminal connection technology. Each lug is manufactured from 99.9% pure T2 grade electrolytic copper (ETP), ensuring maximum electrical conductivity and superior heat dissipation properties. Our seamless construction eliminates weak points and potential failure areas, providing a secure connection that maintains its integrity even under high-current loads and temperature fluctuations.

The precision-engineered barrel features a flared entry design that facilitates easy conductor insertion and ensures proper wire seating. This thoughtful design element not only speeds up installation but also guarantees a more secure crimp by preventing conductor strands from splaying during insertion. The barrel’s carefully calculated thickness provides the ideal balance between flexibility for crimping and structural integrity for long-term performance.

Key Features and Benefits

• Premium Copper Construction: Manufactured from high-conductivity T2 grade copper (99.9% pure) for optimal electrical performance
• Superior Conductivity: Excellent current-carrying capacity with minimal voltage drop
• Enhanced Corrosion Resistance: Available with tin plating that prevents oxidation and extends service life
• Seamless Design: One-piece construction eliminates potential failure points
• Optimized Palm Dimensions: Properly sized connection surfaces ensure full contact with mounting surfaces
• Flared Barrel Entry: Facilitates easy conductor insertion and proper wire seating
• Uniform Wall Thickness: Ensures consistent crimping and reliable connections
• Wide Size Range: Comprehensive sizing from 10mm² to 630mm² to meet diverse application requirements
• Temperature Stability: Maintains performance integrity across a wide temperature range (-50°C to +150°C)
• Vibration Resistance: Maintains secure connections even in high-vibration environments
• Long Service Life: Engineered for decades of reliable performance

Technical Specifications

Our DT Copper Lugs are manufactured to precise specifications to ensure consistent performance across our entire product line:

Model	D ±0.3 (mm)	d ±0.3 (mm)	L ±1.5 (mm)	L1 ±1.5 (mm)	S ±0.3 (mm)	N ±0.5 (mm)	W ±0.5 (mm)	Wall thickness (mm)
DT-10ᵀ	9	5.8	63	30	2.4	8	16	1.6
DT-16ᵀ	10	6.5	65	32	2.6	8	16	1.75
DT-25ᵀ	11	7.5	70	35	3.0	9	18	1.75
DT-35ᵀ	12	8.7	80	38	3.2	10	20	1.75
DT-50ᵀ	14	10.0	85	42	3.4	11.5	23	2.0
DT-70ᵀ	16	12.0	95	47	4.0	13	26	2.0
DT-95ᵀ	18	14.0	103	48	4.5	14	28	2.0
DT-120ᵀ	20	15.5	111	52	4.8	15	30	2.25
DT-150ᵀ	22	17.0	121	56	5.5	17	34	2.5
DT-185ᵀ	25	19.0	125	59	6.0	18	38	3.0
DT-240ᵀ	27	21.5	135	60	6.6	20	40	2.75
DT-300ᵀ	30	23.5	152	68	7.3	25	50	3.25
DT-400ᵀ	34	27.0	170	76	8.5	28	55	3.5
DT-500ᵀ	38	29.0	186	86	9.0	31	55	3.75
DT-630ᵀ	45	35.0	210	86	9.0	31	60	3.75

All dimensions are in millimeters (mm)

DT Copper Lug Dimension

The Science Behind DT Copper Lugs

The exceptional performance of our DT Copper Lugs is rooted in both material science and precision engineering. Copper stands as the industry’s preferred material for electrical conductors due to its inherent properties:

• Electrical Conductivity: With a conductivity rating of 100% IACS (International Annealed Copper Standard), our T2 copper provides unmatched electrical performance, minimizing energy losses and heat generation.
• Thermal Conductivity: Copper’s excellent heat dissipation capabilities prevent hotspots and maintain connection integrity even under high current loads.
• Malleability: The material’s natural flexibility allows for secure crimping while maintaining structural integrity.
• Corrosion Resistance: Copper’s natural resistance to oxidation and corrosion is further enhanced with our optional tin plating, ensuring long-term performance reliability even in challenging environments.

Our engineering team has optimized every dimension of the DT Copper Lug to balance electrical performance, mechanical strength, and installation convenience. The resulting design represents the perfect union of material excellence and thoughtful engineering.

Applications

DT Copper Lugs excel in a wide range of applications where reliable electrical connections are critical:

• Industrial Power Distribution: Connect power cables to switchgear, panel boards, and distribution equipment
• Renewable Energy Systems: Ensure reliable connections in solar and wind power installations
• Commercial Building Infrastructure: Provide secure terminations for building power systems
• Data Centers: Deliver dependable power connections for critical computing facilities
• Manufacturing Equipment: Maintain consistent power delivery to industrial machinery
• Transformer Connections: Create reliable links between transformers and distribution systems
• Motor Controls: Provide stable power delivery to motor control centers
• Grounding Systems: Ensure safe and effective equipment grounding
• UPS and Backup Power Systems: Maintain critical connections in emergency power applications
• Battery Storage Systems: Create reliable connections for energy storage solutions

Installation Best Practices

For optimal performance of your DT Copper Lug connections, we recommend following these installation guidelines:

1. Proper Sizing: Select the appropriate lug size based on your conductor cross-section and bolt hole requirements
2. Clean Preparation: Ensure conductor ends are clean, straight, and free of insulation debris
3. Full Insertion: Insert conductor fully into the barrel until it reaches the inspection window or depth marker
4. Proper Crimping: Use the recommended crimping tool and die that matches your lug size
5. Crimping Sequence: For longer barrels, start crimping at the conductor end and work toward the palm
6. Torque Specifications: When mounting lugs to bus bars or terminals, follow manufacturer-recommended torque values
7. Connection Protection: In corrosive or high-moisture environments, consider using protective covers or heat shrink

Quality Assurance

At VIOX, our commitment to quality is unwavering. Each DT Copper Lug undergoes rigorous testing to ensure it meets our exacting standards and industry requirements:

• Material Verification: Each production batch undergoes chemical composition analysis to confirm copper purity
• Dimensional Inspection: Precision measurements verify compliance with specified tolerances
• Conductivity Testing: Electrical testing confirms the lug meets or exceeds conductivity requirements
• Pull-Out Testing: Mechanical testing verifies the lug’s ability to maintain connection integrity under tensile stress
• Heat Cycle Testing: Performance evaluation under repeated thermal cycling demonstrates long-term reliability

Our DT Copper Lugs are manufactured in compliance with international standards including IEC 61238-1, ensuring consistent quality and performance across our entire product line.

Advantages Over Competing Products

When compared to alternative connection methods or lower-quality lugs, our DT Copper Lugs offer significant advantages:

• Superior Material Quality: 99.9% pure electrolytic copper outperforms lower-grade materials in conductivity and durability
• Optimized Design: Precision engineering ensures perfect balance between electrical performance and mechanical strength
• Comprehensive Size Range: Our extensive product line covers virtually any application requirement
• Consistent Manufacturing: Rigorous quality control ensures every lug delivers the same exceptional performance
• Application Versatility: Suitable for both indoor and outdoor applications with appropriate installation practices
• Long-Term Value: While potentially higher in initial cost than alternatives, the superior performance and longevity deliver exceptional lifetime value

Conclusion

The DT Copper Lug series represents VIOX’s commitment to engineering excellence in electrical connection technology. By combining premium materials with thoughtful design and rigorous quality control, we’ve created a product that delivers exceptional performance, reliability, and value for your most demanding electrical applications.

Choose VIOX DT Copper Lugs for your critical electrical connections and experience the difference that quality engineering makes in system performance, safety, and long-term reliability.