DTL-5 Forged Bimetallic Cable Lug

Advanced Aluminum-to-Copper Transition Technology for Critical Power Infrastructure

The VIOX DTL-5 Forged Bimetallic Cable Lug represents our most robust solution for medium voltage power distribution systems. Specifically engineered for applications requiring exceptional mechanical strength and electrical performance, these premium forged bimetallic lugs provide the ideal transition between aluminum conductors and copper equipment terminals in transformers, switchgear, and other medium voltage infrastructure.

Developed through extensive engineering research and field experience, VIOX ELECTRIC’s DTL-5 series combines superior materials with advanced manufacturing techniques to address the unique challenges of medium voltage connections where reliability is non-negotiable.

Superior Materials and Forged Construction

The DTL-5 series is manufactured using premium materials and specialized forging processes that enhance both mechanical integrity and electrical performance:

• High-Purity Aluminum Barrel: Fabricated with aluminum content ≥99.5% for optimal conductivity with aluminum cables
• Premium Copper Palm: Ultra-pure copper content ≥99.9% ensures maximum electrical efficiency at equipment termination points
• Forged Construction: Advanced forging process creates superior mechanical properties compared to cast or machined connectors
• Friction-Welded Junction: Our molecular bonding technology creates a permanent, high-strength connection between the dissimilar metals

Engineered Features of VIOX DTL-5 Forged Bimetallic Lugs

The DTL-5 series incorporates several specialized engineering features that differentiate it from standard bimetallic lugs:

• Oil Blocking Structure: Specialized design prevents moisture ingress at the critical bimetallic junction
• Pre-filled Joint Compound: Factory-applied anti-oxidation compound eliminates the need for field application and ensures complete coverage
• Optimized Geometry: Enhanced palm-to-barrel ratio distributes mechanical forces appropriately for medium voltage applications
• Extended Barrel Design: Provides superior conductor support and crimp integrity in higher voltage environments

Medium Voltage Applications

The DTL-5 Forged Bimetallic Cable Lugs are specifically designed for critical medium voltage installations:

• Transformer connections in distribution networks
• Medium voltage switchgear terminations
• Aerial Bundled Cable (ABC) connections to equipment
• Hệ thống phân phối điện công nghiệp
• Utility infrastructure upgrades
• Renewable energy integration points
• Applications requiring superior mechanical strength

Professional Installation Guidelines

To ensure optimal performance in medium voltage applications, VIOX ELECTRIC recommends following these professional installation procedures:

1. Select the appropriate DTL-5 lug size based on conductor cross-sectional area
2. Use professional-grade insulation stripping tools to prepare the aluminum conductor end
3. Ensure complete conductor insertion into the aluminum barrel
4. Use medium voltage-rated heat-shrink insulation sleeve at the connection interface
5. Apply calibrated compression tools with die sets specifically rated for medium voltage applications
6. Torque the terminal connection to the equipment manufacturer’s specifications
7. Perform thorough visual inspection and electrical testing of the completed connection

Critical Safety Precautions for Medium Voltage Installations

Given the higher voltages involved, observe these essential safety measures when installing DTL-5 bimetallic lugs:

• Only qualified personnel should perform medium voltage connections
• Verify complete de-energization and lockout/tagout of electrical circuits
• Use voltage detection equipment rated for medium voltage applications
• Follow utility-specific safety protocols for medium voltage work
• Use appropriate personal protective equipment (PPE) for medium voltage environments
• Verify conductor and lug compatibility before installation
• Ensure proper insulation and clearances for medium voltage operation

Thông số kỹ thuật

Dimensional Legend: φ = Palm Hole Diameter, D = Aluminum Barrel Outer Diameter, d = Aluminum Barrel Inner Diameter, L = Total Length, L1 = Aluminum Barrel Length, W = Palm Width

Kích thước

The Critical Importance of Specialized Bimetallic Lugs for Medium Voltage

Medium voltage applications present unique challenges that standard bimetallic connectors may not adequately address. These systems frequently experience more significant thermal cycling, higher mechanical stresses, and potentially more severe environmental exposure than low voltage installations. The consequences of connection failure at medium voltage are also typically more severe.

The DTL-5 Forged Bimetallic Cable Lug addresses these challenges through its forged construction, which provides superior mechanical strength and fatigue resistance compared to standard connectors. The enhanced oil blocking structure and pre-filled joint compound work together to maintain connection integrity even under the more demanding conditions typical of medium voltage environments.

The VIOX ELECTRIC Advantage in Medium Voltage Applications

With extensive experience in power transmission and distribution solutions, VIOX ELECTRIC brings several distinct advantages to our DTL-5 Forged Bimetallic Cable Lug product line:

• Specialized Engineering: Our R&D team focuses on designing application-specific solutions for medium voltage power infrastructure
• Advanced Manufacturing: Forging processes enhance the mechanical and electrical properties beyond what can be achieved with standard manufacturing techniques
• Kiểm tra toàn diện: Every batch undergoes rigorous electrical and mechanical testing to verify conformance to international medium voltage standards
• Global Distribution: VIOX products are available worldwide through our extensive distribution network
• Hỗ trợ kỹ thuật: Our engineering team provides expert guidance for medium voltage applications and installation best practices

Contact VIOX ELECTRIC today to discuss how our DTL-5 Forged Bimetallic Cable Lugs can enhance the reliability and performance of your medium voltage connections. Our technical specialists are ready to assist with product selection, application guidance, and ordering information to ensure you receive the optimal solution for your specific medium voltage requirements.