DTS Two-Hole Copper Lug

Welcome to VIOX’s premier DTS Two-Hole Copper Lug series, engineered specifically for applications where connection reliability and stability are paramount. Crafted from high-conductivity electrolytic copper and featuring a robust two-hole design, the DTS series delivers exceptional electrical performance while preventing connection rotation and maintaining superior mechanical integrity in even the most demanding environments.

Engineered for Ultimate Connection Stability

The DTS Two-Hole Copper Lug represents the pinnacle of electrical connection technology. Each lug is manufactured from 99.9% pure electrolytic copper (ETP grade), ensuring maximum electrical conductivity, minimal heat generation, and superior performance in high-current applications. The precision-engineered barrel features an optimized wall thickness and flared entry design, facilitating easy conductor insertion while maintaining structural integrity for long-term connection reliability.

What truly sets the DTS series apart is its dual-hole palm design. This configuration provides significantly improved connection stability compared to single-hole alternatives, effectively eliminating the risk of rotation under mechanical stress or during fault current events. The two mounting points distribute connection forces more evenly across the lug surface, creating a more secure and reliable termination point that maintains consistent contact pressure over time – a critical factor in reducing connection resistance and preventing hotspots.

Key Features and Benefits

• Dual-Hole Design: Prevents rotation and maintains connection integrity even under extreme mechanical stress or fault conditions
• Premium Copper Construction: Manufactured from high-conductivity T2 grade electrolytic copper (99.9% pure) for optimal current flow
• Enhanced Contact Area: Larger palm surface provides improved current distribution and lower contact resistance
• Exceptional Conductivity: Minimizes voltage drop and reduces energy losses in high-current applications
• Optimized Barrel Design: Precisely engineered for secure crimping and maximum conductor retention
• Superior Corrosion Resistance: Available with tin plating to prevent oxidation and extend connection lifespan
• Consistent Spacing: Standardized hole spacing compatible with common busbar and terminal configurations
• Comprehensive Size Range: Available in sizes from 35mm² to 400mm² to accommodate various application requirements
• High Temperature Stability: Maintains connection integrity across a wide temperature range (-50°C to +150°C)
• Vibration Resistance: Two-point fixing provides superior stability in high-vibration environments
• International Standards Compliance: Manufactured to meet IEC 61238-1 and other relevant industry standards

Technical Specifications

Our DTS Two-Hole Copper Lugs are manufactured to precise specifications, ensuring consistent performance and reliability across our entire product range:

All dimensions are in millimeters (mm)

DTS Two-Hole Copper Lug Dimension

The Science Behind Two-Hole Lugs

The superior performance of the DTS Two-Hole Copper Lug is grounded in both materials science and mechanical engineering principles. Two-hole lugs address several critical challenges in electrical connections that single-hole alternatives cannot match:

Prevention of Rotation

In high-stress applications, particularly those involving fault currents, single-hole lugs can rotate under extreme mechanical forces. This rotation can reduce conductor spacing, potentially leading to phase-to-phase or phase-to-ground faults. The dual-mounting point design of DTS lugs effectively prevents this rotation, maintaining proper clearances even under extreme conditions. This superior stability can be the difference between a system that maintains integrity during a fault event and one that experiences catastrophic failure.

Enhanced Contact Area

The two-hole design inherently provides a larger contact area between the lug and the mounting surface. This increased area distributes electrical current more evenly, reducing the risk of hotspots and minimizing connection resistance. Lower resistance connections not only improve system efficiency but also reduce heat generation, extending the life of both the connection and surrounding components.

Superior Mechanical Stability

Electrical connections often experience mechanical stress from thermal cycling, vibration, and physical movement. The dual-fixing points of the DTS lug provide significantly improved resistance to these stresses, maintaining consistent contact pressure over time. This enhanced stability is particularly valuable in applications subject to vibration or thermal expansion and contraction cycles.

Applications

The DTS Two-Hole Copper Lug excels in critical applications where connection reliability is essential:

• Power Distribution Panels: Provides secure connections between main feeders and busbars
• Industrial Motor Controls: Ensures stable power delivery in high-vibration environments
• Switchgear Equipment: Maintains connection integrity during fault conditions
• Renewable Energy Systems: Delivers reliable connections in solar and wind power installations
• UPS and Backup Power Systems: Provides dependable connections for emergency power applications
• Data Center Infrastructure: Ensures consistent power delivery for critical computing facilities
• Transformer Connections: Creates stable links between transformers and distribution systems
• Railway Signaling and Power: Maintains connection integrity in high-vibration transportation systems
• Marine and Offshore Applications: Provides corrosion-resistant connections in harsh environments
• High-Current Industrial Equipment: Ensures secure connections for welding equipment, furnaces, and similar applications

Installation Best Practices

To achieve optimal performance from your DTS Two-Hole Copper Lug connections, we recommend following these installation guidelines:

1. Select the Appropriate Size: Choose the correct DTS lug model based on your conductor cross-section and application requirements
2. Prepare the Conductor: Ensure the conductor is clean, properly stripped, and free of nicks or damage
3. Insert Fully: Insert the conductor completely into the barrel until it reaches the inspection window or depth marker
4. Use the Proper Crimping Tool: Select a crimping tool and die matched to the lug size and rated for the application
5. Follow Crimping Sequence: For larger lugs, begin crimping at the conductor end and work toward the palm
6. Apply Proper Torque: When mounting the lug, use calibrated torque tools to achieve the recommended bolt torque values
7. Ensure Even Connection: Verify that both mounting points are secured with equal pressure
8. Apply Appropriate Inhibitor: In outdoor or corrosive environments, use suitable joint compound or anti-oxidation paste

Quality Assurance

At VIOX, quality is the foundation of everything we do. Each DTS Two-Hole Copper Lug undergoes rigorous testing and inspection to ensure it meets our exacting standards:

• Material Verification: Chemical composition analysis confirms copper purity exceeds 99.9%
• Dimensional Inspection: Precision measurements verify compliance with specified tolerances
• Conductivity Testing: Electrical testing confirms optimal conductivity performance
• 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
• Fault Current Testing: Verification of mechanical stability under high-current fault conditions

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

Why Choose VIOX DTS Two-Hole Copper Lugs?

When compared to alternative connection methods or standard single-hole lugs, our DTS Two-Hole Copper Lugs offer significant advantages:

• Enhanced Safety: Superior connection stability reduces the risk of electrical failures and potential hazards
• Improved Reliability: Dual-fixing points maintain connection integrity even under extreme conditions
• Higher Fault Current Ratings: Improved mechanical stability allows for higher short-circuit current ratings
• Reduced Maintenance: Stable connections remain secure longer, reducing the need for periodic re-torquing
• Extended Equipment Life: Lower connection resistance reduces heat generation and stress on connected equipment
• Comprehensive Product Range: Available in multiple sizes to meet diverse application requirements
• Superior Manufacturing: Precision engineering and rigorous quality control ensure consistent performance
• Expert Technical Support: Our engineering team provides application-specific guidance for optimal results

Conclusion

The DTS Two-Hole 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 safety for your most critical electrical connections.

Choose VIOX DTS Two-Hole Copper Lugs for applications where connection failure is not an option, and experience the difference that superior engineering makes in system performance, safety, and long-term reliability.