Telexc TX DTL-2 Bimetallic Cable Lug – Aluminum to Copper

DTL-2 Bimetallic Cable Lug – Aluminum-to-Copper Transition

Key Features

  • Bimetallic design for aluminum-to-copper transitions

  • Premium friction-welded junction for permanent molecular bonding

  • Pre-applied anti-oxidation compound prevents galvanic corrosion

  • Oil-blocking structure protects from moisture ingress

  • Precision-machined aluminum barrel ensures accurate crimping

  • Enhanced copper palm maximizes contact surface for secure connections

  • Available in sizes from 10 mm² to 630 mm²

Category: Tags: , , , , , ,

The Telexc TX DTL-2 Bimetallic Cable Lug provides a safe, corrosion-free, and high-performance solution for connecting aluminum conductors to copper terminals. Engineered with premium friction-welded technology and pre-applied anti-oxidation compound, these lugs ensure reliable electrical connections in low-voltage distribution, industrial systems, and renewable energy installations. Ideal for professional-grade applications, the DTL-2 series guarantees optimal conductivity and long-lasting performance.

International Standard Compliance

  • IEC 61238-1: Crimping of electrical connectors

  • RoHS Compliant

  • Meets low-voltage distribution safety standards

Construction & Materials

  • Aluminum Barrel: ≥99.5% pure aluminum for optimal conductivity

  • Copper Palm: ≥99.9% pure copper for reliable terminations

  • Friction Weld: Advanced metallurgical bonding for a permanent joint

  • Joint Compound: Factory-applied anti-oxidation paste

Types of Bi-metallic Lugs & Connectors – Telexc

Telexc offers a comprehensive range of bi-metallic lugs and connectors, with customization available to meet specific project and application requirements. The following variants can be manufactured as per customer specifications:

  1. Bi-metallic Lugs – Aluminum barrel with copper palm, available in single-hole, double-hole, or four-hole palm designs.

  2. Bi-metallic Lugs with Copper Washer – Aluminum lug integrated with a copper washer to enhance conductivity and joint reliability.

  3. Reverse-Type Bi-metallic Lugs – Copper barrel combined with an aluminum palm for specialized termination needs.

  4. Bi-metallic Connectors (Straight Type) – Designed for aluminum and copper conductors of the same cross-section.

  5. Bi-metallic Connectors (Reducing Type) – Suitable for connecting aluminum and copper conductors of different cross-sections.

  6. Bi-metallic Pin Connectors – Aluminum barrel with a solid copper pin for secure and efficient electrical connections.

Installation Guide

  1. Select DTL-2 lug based on conductor cross-section.

  2. Strip insulation from aluminum conductor using proper tools.

  3. Insert conductor fully into the aluminum barrel.

  4. Place heat-shrink insulation sleeve before crimping.

  5. Crimp using calibrated dies for uniform compression.

  6. Inspect connection for integrity, proper insulation, and no exposed copper.

  7. Mount copper palm securely onto terminal using correct bolts or screws.

Safety Precautions:

  • Ensure circuits are fully de-energized and locked out.

  • Verify voltage absence with approved testers.

  • Confirm conductor and lug compatibility.

  • Use only industry-approved crimping tools.

  • Inspect all connections before energizing.

Technical Specifications

Model φ ±0.3 (mm) D ±0.2 (mm) d ±0.2 (mm) L ±2 (mm) L1 ±2 (mm) W ±0.2 (mm)
TX-DTL-2-10 13 16 5.2 80 44 20
TX-DTL-2-16 13 16 6.5 80 44 20
TX-DTL-2-25 13 16 7.5 80 44 20
TX-DTL-2-35 13 16 9 80 44 20
TX-DTL-2-50 13 20 10 90 44 24
TX-DTL-2-70 13 20 11 90 44 24
TX-DTL-2-95 13 20 12.5 90 44 24
TX-DTL-2-120 13 25 15 118.5 60 30
TX-DTL-2-150 13 25 15.5 118.5 60 30
TX-DTL-2-185 13 32 18.5 120 60 35
TX-DTL-2-240 13 32 20.5 125 60 35
TX-DTL-2-300 13 34 22.5 132 72 36
TX-DTL-2-400 17 40 27 141 72 36
TX-DTL-2-500 17 40 29.5 141 72 36
TX-DTL-2-630 17 47 34 185 100 45

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

Applications

  • Low-voltage power distribution networks

  • Industrial control panels and machinery

  • Commercial electrical infrastructure

  • Renewable energy and solar installations

  • Aluminum feeder connections in building systems

  • Motor and transformer terminations

Product Advantages

  • Eliminates galvanic corrosion at aluminum-copper junctions

  • High conductivity ensures minimal voltage drop

  • Long service life with pre-applied protective compound

  • Wide range of sizes for flexible application

  • Reliable performance in industrial and commercial environments

FAQs

Q1: Can DTL-2 lugs be used directly on copper conductors?
A: No, these lugs are specifically designed for aluminum-to-copper transition.

Q2: What crimping tools are compatible?
A: Calibrated die sets for bimetallic friction-welded lugs.

Q3: Are these lugs pre-filled with anti-corrosion paste?
A: Yes, factory-applied joint compound prevents galvanic corrosion.

Q4: What is the maximum conductor size?
A: Up to 630 mm².

Q5: Can they be customized?
A: Yes, Telexc can produce according to customer drawings.

Q6: Are these suitable for outdoor installations?
A: Yes, with proper insulation and installation, they are suitable for industrial and commercial outdoor use.

Why Choose Telexc

  • Advanced manufacturing with rigorous quality control

  • Fast delivery and competitive pricing

  • Technical support for installation and sizing guidance

  • Trusted for industrial, commercial, and renewable energy applications

Related products