UTILUX REFERENCE MANUAL - GV K

1 Power ProductsReference ManualUTILUXU tilux is a brand that has built an enviable reputation for high quality, reliable electrical connectors. For over 80 years,this dynamic Australian brand has been a leader in the field of interconnection systems. UTILUX has now joined thetruly innovative, international market leader, Tyco aim is to provide the best possible products and services to keep our customers at the cutting edge of industrystandards - YOU CAN RELY ONThe UTILUX manufacturing operation is certified to International Standards Organisation (ISO) 9001:2000 qualitystandards, the benchmark for the worlds best practice in design and production facilities and methods. Tyco s highlyskilled technical team ensures that these optimal standards are inherent in every product that leaves our factories. You can be sure that UTILUX branded products are fabricated from the finest materials and produced to exactingtolerances.

2 They represent the latest technology and the best design for the tasks they are required to ELECTRICAL CONNECTORSU tilux is a leading brand of electrical connectors sold to original equipment manufacturers and electrical distributioncompanies throughout Australia, New Zealand and Asia. A comprehensive range, the most up to date productiontechnology and the highest quality control standards ensure that there are UTILUX connectors, of optimum reliabilityand durability, for all major power distribution FACILITYL ocated within Tyco Electronics Energy Division s Wyong manufacturing facility is the largest NATA accredited testfacility owned and operated by a manufacturing supplier within the Australian and New Zealand market place. Full test facilities are available, whether electrical, mechanical or environmental. RESEARCH & DEVELOPMENTAs part of the worlds largest electrical connector company, the development of products is an ongoing commitment.

3 It is done on a global basis, utilising the talents of many people throughout the organisation to ensure a globalproduct for a local market. TECHNICAL ASSISTANCEW hether dealing direct with Tyco Electronics Energy Division or a Distributor, a full team of experienced technicalsales and support people are available to assist in the purchase of products shown in the catalogue or to develop a solution to meet your particular catalogue is correct at the time of printing but due to ongoing design reviews and product development, Tyco Electronics Energy Division reserves the right to modify the specification of any product without 2003 COPPER CONDUCTOR TERMINATIONSCATALOGUE INDEXCONTENTSSECTION1 INDEXSECTION 1 COPPER CONDUCTOR TERMINATIONS .. 1 COPPER CRIMP LUG .. 2 CIRCUIT BREAKER LUGS .. 4 COPPER FLARED LUGS .. 5 COPPER CRIMP LINKS.

4 6 COPPER CRIMP LINKS WITH SOLID BARRIER .. 7 REDUCING LINKS .. 8 COPPER STALK LUG TYPE 1 .. 9 COPPER STALK LUG TYPE 2 .. 9 CRIMP CABLE CONNECTOR .. 9 CABLE LUG SOLDER TYPE.. 10 SEALED COPPER CRIMP LUGS .. 10 BOLTED CABLE LUG.. 11 BOLTED TEE CLAMP.. 11 CAST LUGS .. 11 C CONNECTORS .. 12 SOLID PALM COPPER LUGS .. 13 COPPER CRIMP LUG Suitable for copper conductor Range mm2 Seamless copper tube Electro tinned Cable area clearly identified on the lug Tested to AS/NZS (mm2)NO. OF CRIMPS (Tool No.)CRIMPINGSIZEAB CDFG76 0018202122 * * * * (mm2)

5 CONDUCTORSTRANDING38-44CU38-57CU38-63CU3 8-77CU38-70 CUAll sizes of crimp lugs are compatible with imperial size cables except those marked* CONDUCTOR TERMINATIONS3 COPPER CONDUCTOR (mm2)NO. OF CRIMPS (Tool No.)SIZEAB CDFG20212238A * * * * * * * * *

6 *630127 (mm2)CONDUCTORSTRANDINGCRIMPINGDIE38-92C U38-104CU38-115CU38 -142CU40-142CU38 -165CU40-165CU38 -183CU40-185CU38 -200CU40-200CU38 -231CU40-231CU38 -260CU40-260CU40-281CU50-281CU66-281CU40 -370CU50-370CU40-310CU50-310CU66-310CU35 50709512015018524030040050019 H1438 Sleeved to suit 19/.0831 NARROW PALM Specially made for terminating large cables to circuit breakers Unique bell mouth for easy insertion of fine stranded conductors Made for + high conductivity copper4 CAT mmNO. OF CRIMPS (Tool NO.) CONDUCTOR TERMINATIONSCOPPER FLARED LUGSThe range of flared copper lugs has been designed with the barrel entry flared to enable an easy insertion of multistranded cables (flexible cable).

7 The range of connectors (from 25mm2to 185mm2) will ensure most applications forthe common flexible cable sizes are covered. The flared copper lugs are made from seamless copper tube, electro tinplated and have the cable area clearly marked on the palm of the lug. The inspection window on the barrel provides a check that the cable has been fully inserted. The flared lugs can be crimped with the standard range of UTILUX tooling and hexagonal STRANDINGBOLT DIMENSIONS (mm)NO. OF CRIMPS (Tool No.)CRIMPINGSIZE (mm2)METRICSIZEABDF20212238A40 BDIECG25 FLM6209 CONDUCTOR TERMINATIONS16 COPPER CONDUCTOR TERMINATIONSCOPPER CRIMP LINKS Solid drawn copper tube Centre dimples Ends reamed CONDUCTORSTRANDINGDIMENSIONS OF CRIMPS (TOOL NO.) *15037 *630127 sizes of crimp links are compatible with imperial size cables except those marked*whateveryouneedCANHELP7 COPPER CRIMP LINKS WITH SOLID BARRIER For use with oil filled cables Solid drawn copper rod Electro tinned Solid centre barriers Ends OF CRIMPS (Tool No.)

8 CRIMPING AREA CONDUCTOR TERMINATIONSCRIMP CABLE CONNECTOR Seamless drawn Copper tube Electro tinnedCAT mmSTYLETOOL , 16B, , 16B, , 16B, 76B, , 16B, 76B, , 16B, 76B, 18AH20422 x 24 , 16B, 76BH20222 x 50 , 16B, 18AH20273 x 32 , 16B, 18, 76BH20433 x 32 , 16B, 18, 76BH20295 x 32 , 16B, 18AH20412 x 50 , 38A, 21, 2218 LARGE ENDSMALL :CRIMPING DIMENSIONS:CRIMPING AREA LINKS Solid drawn copper rod Electro tin plated Stock sizes shown Custom sizes to order Crimp with standard UTILUX hex diesAny size can be made for items not shown above complete UTILUX Express form on page 103 and fax to our manufacturing site on (02) 4353 247038-63CU38-77CU38-92CU38-104CU38-115C U38-142CU38-165CU38-183CU38-200CU38-231C U40-231CU38-260CU40-260 CUCOPPER CONDUCTOR (mm)CRIMPINGAREA mm2 METRICABDFDIECS1-35/8H23093519 CS1-95/10H23319537 mmCRIMPINGAREA mm2 METRICABDFDIECS2-16/8H23417.

9 Conductor areas indicated for STYLE 1 are combined areas of wire to be spliced1625355038-63CU38-77CU38-92CU38-1 04 CUCOPPER CONDUCTOR TERMINATIONSCOPPER STALK LUG TYPE 1 Electro tinned finish Alternative sizes made to orderCOPPER STALK LUG TYPE 2 Electro tinned finish Alternative sizes made to order110 SEALED COPPER CRIMP LUGS Long barrel length for effective heat shrink sealing Designed for outdoor terminations Solder sealed Impervious to air at 140 kPa minCABLE LUG SOLDER TYPE Solid drawn copper tube Electro tinned Alternative sizes made to order Not recommended for crimping Bright acid tin finish for easy AREANOMINAL AMPSSTUDDIMENSIONS mmmm2 FOR CU CABLESIZE STRANDINGSTUDDIMENSIONS (mm)CRIMPINGAREA mm2 METRICSIZEAB CONDUCTOR TERMINATIONS11 CAST LUGS Made to custom requirements Made to approved order, quantities only Copper alloy, however can be made in other materials Type of applications; diesel electric loco transformers special applicationCOPPER CONDUCTOR TERMINATIONSLONG PALM LONG BARREL COPPER CRIMP LUGS Long barrel length for effective heat shrink sealing No inspection window Uses same crimp tools as standard copper mmCRIMPINGP/NAREA CONDUCTOR TERMINATIONSBOLTED CABLE LUG Quick and easy termination Re-usable Palms are machined flat and parallel for maximum conductivity Copper FLEXIBLESTUDDIMENSIONS mmCODEAREA mm2 CONDUCTORSIZEABCD7/.

10 085BG1H1801NO. 14-107 2167 325-3519 450-7019 *H1804 CNO. 4C50-7019 59537 612037 6150-18537 7185-24061 8300-40061 950061 TEE CLAMP Provide quick and easy tee offs Copper alloy H1820 and H1821 can be used with slottedpalm lugs for easy disconnect CABLE RANGETEE CABLE RANGEDIMENSIONSMINMAXMINMAXABTG185240H18 18185mm2240mm270mm295mm28133TG5070H18205 0mm270mm2--7932TG7095H182170mm295mm2--87 70*C = Slot 12mm wide instead of bolt hole13 COPPER CONDUCTOR TERMINATIONS C CONNECTORSC-Connectors are manufactured in C shaped copper section for connection of main and tap copper conductors. Reliability is ensured by passing tests specified by JIS C 2810 Suitable for connecting copper conductors in both indoorand outdoor applications such as earth grid connections Tin plated Other sizes available on request (366-700mm2) mm2 HWL CDie Part to 1196124# to 16128135#18C-CC20T-02014 to 20131013538-T020T-020 CCC25T-02621 to 26151116638-T026T-026 CCC35T-04427 to 44191420838-T044T-044 CCC50T-06045 to 602115221038-T060T-060 CCC70T-07661 to 762417221138-T076T-076 CCC95T-09877 to 982819251438-T098T-098 CCC120T-12299 to 1223021261338-T122T-122 CCC150T-154123 to 1543424281738-T154T-154 CCC185T-190155 to 1903725351738-T190T-190 CCC240T-240191 to 2404028401938-T240T-240 CCC300T-288241 to 2884531452238-T288T-288 CCC400T-365289 to 3654834502438-T365T-365 CCONDUCTOR TAP CONDUCTOR mm2 CWHL = Connector Length114 COPPER CONDUCTOR TERMINATIONSCAT mmCRIMPING DIEAREA PALM COPPER LUGSU tilux have introduced a range of small copper lugs to be used in heavyindustry.