A cable lug is a metal connector used to terminate electrical cables by providing a secure and conductive connection to another component, such as a terminal, busbar, or switchgear. Shear head bolts are a specific type of bolt that, once tightened to the correct torque, break off or "shear" at a predetermined point. This ensures that the correct pressure is applied to the connection, preventing over-tightening or under-tightening.
For 1-11kV power lines, these lugs are engineered to meet the requirements of medium-voltage systems, where both safety and reliability are paramount. The pre-insulated design, combined with the shear head bolt mechanism, makes them especially effective for these high-voltage applications.
Benefits of Mechanical cable lug with shear head bolts for 1-11KV power lines
Enhanced Safety:
● Pre-insulation: Minimizes the risk of electrical shock and short circuits.
● Consistent Clamping: Shear head bolts ensure consistent clamping force, reducing the risk of loose connections and potential failures.
Improved Installation Efficiency:
● Shear Head Bolts: Eliminate the need for torque wrenches, speeding up installation.
● Pre-insulation: Can simplify the installation process.
Reliable Performance:
● Consistent Clamping: Ensures a secure and reliable connection with low contact resistance.
● Durable Construction: Withstands harsh environmental conditions.
Cost-Effectiveness:
● Faster Installation: Leads to significant labor cost savings.
● Reliable Connections: Minimize downtime and maintenance costs.
Jera line produce CLBIT-2-70-240 comply to IEC-61238-1-3, three zones of torque shear bolts,applied with copper and aluminum.
Applications for 1-11kV Power Lines:
1. Industrial Power Supply:
Large industrial plants, factories, and facilities with medium-voltage electrical systems use these lugs to make secure cable connections to distribution boards, motors, and other equipment that operates in the 1-11kV range.
2. Renewable Energy Systems:
Pre-insulated shear head bolt lugs are used in renewable energy applications, such as wind and solar power plants, to ensure secure, reliable connections for the medium-voltage power lines that transport energy to the grid.
3. Electric Utilities:
Electrical utility companies use these cable lugs for maintenance and installation of medium-voltage cables in their distribution networks. The shear head bolt mechanism ensures quick, reliable, and safe connections during system upgrades and repairs.
Key Features of Mechanical Cable Lugs with Shear Head Bolts for 1-11kV Power Lines:
1. Shear Head Bolt Mechanism:
● Precise Torque Control: The shear head bolt ensures the lug is tightened to the correct torque without the need for a torque wrench. When the bolt reaches the correct tension, the head of the bolt shears off, indicating that the optimal installation force has been applied.
● Prevents Over-tightening: The shear head prevents over-tightening, which could damage the conductor or the terminal. This ensures a safe, secure, and reliable electrical connection.
● Easy Installation: The shear head bolt simplifies the installation process, making it faster and reducing the risk of installation errors.
2. Pre-Insulated Design:
● Safety: The lug is often pre-insulated with PVC or another insulating material, which protects against electrical shock and prevents the exposure of live conductors. This is particularly important in 1-11kV applications, where high voltages can pose significant safety risks.
● Environmental Protection: The pre-insulation also protects the connection from environmental factors such as moisture, dirt, and corrosion, ensuring long-lasting performance in outdoor or industrial environments.
3. High Conductivity Material (Copper/Aluminum):
● Material Choice: The lug is typically made of high-conductivity copper or aluminum to ensure efficient power transmission with minimal energy loss. These materials are ideal for medium-voltage applications as they provide good electrical conductivity and durability.
● Corrosion Resistance: Many of these lugs are treated with corrosion-resistant coatings, such as tin-plating (for copper) or other protective finishes, to withstand the elements, especially in harsh outdoor environments or coastal areas with high humidity.
4. Robust Mechanical Design:
● Vibration Resistance: The mechanical shear head bolt provides a strong, vibration-resistant connection, which is essential in power distribution systems that may be exposed to mechanical stress, wind, and vibrations from nearby equipment.
● High Mechanical Strength: These lugs are designed to handle the mechanical stresses associated with high-voltage cables, ensuring they remain securely attached to the power line terminals under varying conditions.
5. Compatibility with Medium-Voltage Cables:
● Cable Size Compatibility: The lug is designed to work with specific cable sizes and conductor types used in 1-11kV power lines. It accommodates both copper and aluminum conductors, which are common in medium-voltage power distribution.
● Suitable for Aerial and Underground Installations: These lugs are used for both aerial power lines (overhead) and underground power lines, ensuring a secure connection in both scenarios.
6. Pre-assembly or Tool-Free Installation:
● In many cases, these cable lugs may come pre-assembled, ready for installation, and allow for tool-free or minimal tool installation. The shear head bolt does not require additional torque tools beyond a standard wrench or screwdriver.
7. High Voltage Insulation Properties:
● These cable lugs are specifically engineered to safely handle the voltage range from 1kV to 11kV, making them a reliable choice for medium-voltage distribution systems. The pre-insulation also helps prevent short circuits and reduces the risk of electric shock during installation and operation.
1. Cable Insertion: The stripped end of the cable is inserted into the lug.
2. Clamping: The mechanical system (bolts, screws) is tightened, compressing the cable within the lug. This creates a strong electrical and mechanical bond.
Purpose:
● Secure Connection: Its primary function is to provide a strong and reliable connection between a cable and other electrical equipment like:
● Distribution boards
● Switchgear
● Transformers
● Control panels
Cable lugs with shear head bolts are a reliable and efficient solution for connecting 1-11kV power lines. Their pre-insulated design, combined with the shear head bolt mechanism, ensures that the connections are safe, secure, and maintenance-free. These lugs are designed to withstand harsh environmental conditions, making them ideal for outdoor, industrial, and high-voltage applications.
By using shear head bolt cable lugs, utility companies and industrial facilities can ensure long-lasting, high-performance connections that minimize the risk of failures and reduce the need for frequent maintenance. Whether you're installing new power lines, upgrading existing systems, or performing routine maintenance, these lugs are an essential component for reliable and efficient power distribution at medium voltages.
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