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Why Use Standards-compliant Connectors?

Copper connectors are used to join or end a Copper conductor. These connectors are made of high conductivity Copper tube with suitable thickness. A lug should have sufficient palm area and barrel length, whilst a link should have sufficient link length, and plated with Tin to prevent corrosion. 

 

Copper has many grades. For electrical purposes, the Electrolytic Copper (E.Cu) with purity 99.9% and conductivity 99% I.A.C.S. is always used. Using low quality recycle copper is not recommended, as the conductivity is between 50% to 85%.

 

To illustrate this point, we look at the comparison chart below between compliant and non-compliant cable lugs according to MS 1540:2002. You can see that for the supposedly same size cable lug, a non-compliant cable lug has lower conductivity, less wall thickness and shorter length. The result is that the current capacity of the cable lug is greatly affected.

 

 

 

Cable Lug Compliant to MS 1540:2002

Non-compliant  Cable Lug

Cable Lug Compliant to MS 1540:2002

Non-compliant  Cable Lug

Size

300mm2

240mm2

Max. PVC Wire Current Rating in 3 Phase

561 A

485 A

Weight

299 gram

215 gram

(less 28.1%)

212 gram

137 gram

(less 35.3%)

Length

110.1 mm

101.5 mm

(less 7.8%)

103.7 mm

91.1 mm

(less 12.1%)

Wall Thickness

3.9 mm

3.2 mm

(less 17.9%)

3.3 mm

2.6 mm

(less 21.2%)

Conductivity

99%

57%

(less 42%)

99%

83%

(less 16%)

Results

Current rating is 561 A

224 A

(less 59.9%)

Current rating is 485 A

304 A

(less 37.2%)

                           

                        Comparison between Compliant and Non-compliant Cable Lugs

 

 

In the example of the 300mm2 cable lug, the current capacity for the compliant lug is 561A, as compared to 224A for a non-compliant lug. There is a 59.9% reduction in current capacity.  

 

As for the 240mm2 cable lug, the compliant lug registered a current capacity of 485A while the non-compliant lug at only 304A, a 37.2% less in the current capacity.

 

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