Welcome to VIOX, your trusted partner for high-quality electrical connection solutions. We are proud to present the VIOX DL series Aluminium Cable Lug, a cornerstone product designed for secure, efficient, and long-lasting termination of aluminium conductors. Whether you’re working on power distribution networks, industrial installations, or renewable energy projects, choosing the right connector is paramount. The VIOX DL Aluminium Cable Lug range offers exceptional performance and reliability, ensuring the integrity of your critical electrical systems.

Understanding the unique properties of aluminium conductors is key to establishing safe and durable connections. Our DL series aluminium terminal lugs are specifically engineered to address these properties, providing a robust solution for connecting aluminium cables to switchgear, busbars, transformers, and other electrical equipment.

What is an Aluminium Cable Lug?

An Aluminium Cable Lug, often referred to as an aluminium terminal lug or aluminium compression lug, is an essential electrical component used to terminate the end of an aluminium conductor (cable/wire). Its primary function is to create a secure and low-resistance connection point, allowing the aluminium cable to be safely and effectively bolted onto a terminal block, busbar, circuit breaker, or other compatible electrical device.

These lugs typically feature a barrel, where the stripped aluminium conductor is inserted, and a palm (or tongue), which has a hole for fastening (usually with a bolt or screw). The connection is made permanent and electrically sound through a process called compression crimping, which uses specialized tools and dies to deform the barrel onto the conductor, creating a solid, homogenous mass that minimizes electrical resistance and prevents ingress of moisture or contaminants.

Why Choose VIOX DL Aluminium Cable Lugs?

Selecting VIOX DL aluminium cable connectors means investing in quality, reliability, and ease of use. Here’s why our DL series stands out:

Superior Material Quality: Our DL lugs are manufactured from high-conductivity, high-purity aluminium (typically electrolytic grade, >= 99.5% Al). This ensures optimal electrical performance with minimal resistance and heat generation. The material is also specifically chosen for its excellent crimping properties.
Engineered for Aluminium Conductors: Aluminium has unique characteristics, including rapid surface oxidation and a tendency to ‘creep’ (flow under sustained pressure). VIOX DL lugs are designed with appropriate barrel lengths and wall thicknesses to ensure a stable, gas-tight connection after proper crimping, effectively mitigating these challenges. Many standard aluminium lugs benefit from being supplied pre-filled with an oxide-inhibiting compound (jointing paste) to break down the insulating oxide layer during crimping and prevent re-oxidation. Please check specific part number details for pre-filling options.
Reliable Compression Crimping: Designed for standard hexagonal or indent crimping tools, VIOX DL heavy-duty aluminium lugs ensure a consistent and verifiable connection when installed correctly using the appropriate die sets. This method creates a connection with excellent mechanical strength and electrical integrity.
Versatility and Range: The DL series covers a wide array of conductor sizes, from 10 mm² up to 800 mm², accommodating a vast range of applications. Different palm hole sizes may be available to suit various bolt requirements (refer to detailed datasheets or contact us).
Compliance and Quality Assurance: VIOX is committed to delivering products that meet rigorous quality standards. Our manufacturing processes ensure consistency and reliability in every aluminium cable lug we produce.

Key Features of the VIOX DL Series Aluminium Lug

Material: High-Purity Aluminium (>= 99.5%) for excellent conductivity and crimp performance.
Design: Standard barrel design suitable for compression crimping.
Surface: Typically supplied with a bright or matte finish.
Markings: May include markings for conductor size and recommended die set (check specific product).
Compatibility: Designed specifically for terminating stranded or solid aluminium conductors.
Application Standard: Often designed to be compatible with requirements outlined in standards like DIN 46329 or similar specifications for compression lugs (verify specific compliance if required for your project).

Common Applications for Aluminium Cable Termination Lugs

Electrical lugs for aluminium wire like the VIOX DL series are indispensable in numerous sectors:

Power Transmission & Distribution: Connecting underground or overhead aluminium cables in substations and distribution networks.
Industrial Plants: Terminating large power feeds to machinery, control panels, and distribution boards.
Commercial Buildings: Used in main power distribution systems and switchgear installations.
Renewable Energy: Connecting aluminium cables from solar panels (in combiner boxes or inverters) and wind turbines to the grid infrastructure.
Transportation: Applications in railway power supply and infrastructure projects.
Telecommunications: Power systems relying on aluminium conductors.

Technical Specifications: VIOX DL Aluminium Cable Lug Dimensions

Selecting the correct size aluminium cable lug is crucial for a safe and effective connection. The table below provides the key dimensions for the VIOX DL series. Ensure you match the lug’s designated conductor size (e.g., DL-70 for 70 mm² cable) to your specific aluminium cable.

Model	Dimension Ø	D	d	L	L1	A
DL-10	8.5	9	5.5	64	30	15.8
DL-16	8.5	10	6.2	67	32	15.8
DL-25	8.5	12	7.4	75	34	18
DL-35	10.5	14	8.5	85	36	19.7
DL-50	10.5	16	10.0	90	40	23
DL-70	12.5	18	11.8	102	42	26
DL-95	12.5	21	13.5	112	46	28
DL-120	14.5	23	15.0	120	53	30
DL-150	14.5	25	17.0	126	56	34
DL-185	17	27	19.0	133	58	37
DL-240	17	30	21.0	140	60	40
DL-300	21	34	23.5	160	65	50
DL-400	21	38	27	170	72	50
DL-500	21	42	29.2	180	75	60
DL-630	Square palm	54	34.5	225	80	78
DL-800	Square palm	60	38.6	270	90	100

Note: Dimensions are in millimeters (mm). Ø = Outer Diameter of Palm End Area (approx.), d = Inner Diameter of Barrel, L = Overall Length, L1 = Barrel Length, A = Palm Width. Palm type indicates standard shape; variations may exist. Please refer to specific datasheets for precise dimensions and tolerances.

Installation and Best Practices for Crimping Aluminium Cable Lugs

Achieving a reliable connection with an aluminium compression lug depends heavily on correct installation:

Cable Preparation: Strip the aluminium conductor to the correct length (usually matching the barrel length L1). Clean the conductor strands thoroughly using a wire brush to remove the surface oxide layer immediately before insertion.
Use of Jointing Compound: If the lug is not pre-filled, apply a suitable oxide-inhibiting compound liberally to the conductor strands and inside the lug barrel. This prevents re-oxidation and ensures low contact resistance.
Correct Tool and Die Selection: Use a high-quality hydraulic or manual crimping tool specifically designed for aluminium lugs. Select the correct hexagonal or indent die size corresponding to the lug and conductor size (often marked on the lug or specified by the manufacturer). Using the wrong die can result in an under-crimped (loose, high-resistance) or over-crimped (damaged lug/conductor) connection.
Crimping Procedure: Insert the prepared conductor fully into the lug barrel. Perform the required number of crimps according to the tool/die manufacturer’s instructions, typically starting near the palm and working towards the barrel end. Ensure the crimps are properly formed and meet any visual inspection criteria.
Check Connection: After crimping, the connection should be mechanically strong. Visually inspect the crimp for correctness.

Ensuring Longevity: Aluminium Cable Termination Solutions

Properly installed VIOX DL Aluminium Cable Lugs provide excellent long-term performance. To further enhance reliability, especially when connecting aluminium lugs to copper terminals, consider using bimetallic washers or plates to prevent galvanic corrosion. Always ensure bolted connections are tightened to the correct torque specification.

Your Source for Quality Aluminium Cable Lugs

VIOX is dedicated to providing top-tier electrical components like the DL series Aluminium Cable Lug. Our focus on material quality, precise manufacturing, and a comprehensive size range makes us a preferred supplier for demanding applications. We understand the critical nature of electrical connections and strive to offer products that deliver safety and performance.

If you’re looking for reliable aluminium cable termination solutions, explore the VIOX DL series. Contact us today to discuss your specific requirements, request detailed datasheets for models like the DL-10, DL-70, DL-240, or DL-800 aluminium lug sizes, or get a quote. Our team is ready to assist you in selecting the perfect Aluminium Cable Lug for your project.

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