Reducer-Type Aluminum Lugs

Name: Reducer-Type Aluminum Lugs | Transition & Step-down Aluminum Lugs - Frigate
Price: 249.00 USD
Availability: InStock

Mismatched conductor sizes create hot spots and energy loss in power distribution networks, a problem that standard lugs fail to address. Our Reducer-Type Aluminum Schieber solve this with precision-engineered tapered barrels that maintain optimal current flow between different cable sizes.

Material Composition

High-grade aluminum alloy (6063-T6) with electro-tin plating (10-15µm)

Conductor Size Range

Input: 50-400mm² / Output: 16-240mm² (3:1 max reduction ratio)

Current Carrying Capacity

100A-1200A (derated for stepped-down conductor size)

Dimensions

Barrel OD: 15-60mm / Taper length: 30-100mm / Bolt holes: M8-M24

Weight

80g-1.2kg (taper-optimized for weight distribution)

Product Description

Unlike makeshift solutions, these lugs feature a 15° transition zone that reduces current crowding by 40%, verified by thermal imaging at 1200A loads. The dual-compression design ensures UL 486B and IEC 61238-1 compliance, eliminating the safety risks of improvised connections.

Barrel Length

Input side: 25-50mm / Output side: 20-40mm

Termination Type

Dual-compression barrel with tapered transition zone

Crimping Compatibility

Progressive hexagonal dies (40-100kN) for both barrel sizes

Operating Temperature Range

-40°C to +110°C (continuous) / +130°C (short-term)

Surface Finish

Matte tin plating with chromate conversion coating

Voltage Rating

Up to 35kV (IEC 61439-1 tested)

Tensile Strength

200MPa minimum at transition zone

Environmental Resistance

750hr salt spray (ISO 9227 C4) / UV-resistant for outdoor use

Standards Compliance

IEC 61238-1 Class A / UL 486B / BS 573

Installation Method

Sequential crimping (large-to-small conductor) with torque-controlled bolting

Conductor Compatibility

Aluminum-to-aluminum (standard) / Bi-metal versions for Al-Cu transitions

Technical Advantages

Reducer lugs often fail at the taper point, but our 6063-T6 alloy maintains 200MPa tensile strength across the transition zone. The progressive crimping system applies 40-100kN force in sequence, ensuring equal compression on both conductor sizes.

Third-party testing confirms 750-hour salt spray resistance (C4 rating) and 35kV partial discharge performance. Laser-etched size markings on both ends prevent installation errors during maintenance or upgrades.

Let's Get Started

Need reliable Lugs for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Renewable Energy Farms

Transition between main collector cables (400mm²) and inverter inputs (240mm²) while withstanding 35kV surges in solar/wind installations.

Industrial Power Upgrades

Adapt older 300mm² busbars to modern 150mm² equipment feeds without costly panel modifications in factory retrofits.

Data Center Power Chains

Manage precise ampacity transitions between PDUs and server racks, maintaining <1% voltage drop across size changes.

Marine Vessel Electrification

Salt-resistant tinned lugs connect generator outputs (350mm²) to distribution panels (185mm²) in confined engine rooms.

Railway Electrification

Vibration-proof design handles 3:1 reductions in overhead catenary systems, compliant with EN 50152-1.

Mining Mobile Equipment

Withstand 10G vibration while transitioning 240mm² power feeds to 95mm² drill motor connections.

Seamless Current Transition for Mixed-Conductor Systems

Contractors save 60% labor time compared to splicing kits, with no special tools required beyond standard crimpers. Each lug ships with a matched die chart for both barrel sizes, eliminating guesswork in the field.

Procurement teams benefit from stocked size pairs (50-400mm² → 16-240mm²) with full traceability documentation. Custom-marked versions include project IDs and installation dates for asset management compliance.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does the 15° taper design improve performance over standard reducers?

The gradual taper reduces current density spikes by 40% at transition points, verified by infrared thermography at 1200A loads. Unlike abrupt step-down designs, this maintains uniform heat distribution across both conductor sizes. Our testing shows ≤5°C temperature differential even at maximum rated current.

Can one lug handle multiple reduction ratios (e.g., 400mm²→240mm² and 400mm²→185mm²)?

No, each lug is precision-engineered for a single ratio to ensure proper compression depth on both conductors. We stock 18 standard ratios (1.5:1 to 3:1) and offer custom dies for unique requirements. Mismatched ratios risk under-compression and hot spots.

What documentation proves compliance for utility-scale projects?

Every shipment includes IEC 61238-1 Class A test reports with dual-conductor crimp samples, LME aluminum traceability certs, and 35kV partial discharge test data. For North America, we provide UL 486B files with NEMA-approved crimp die charts.

How do you prevent installation errors with dual crimping requirements?

Laser-etched arrows indicate the proper crimping sequence (large→small conductor), while color-coded die charts match our tooling partners (Greenlee, Klauke). Training videos showing the 2-step crimp process are available via QR code on each lug.

What's the lead time for custom bi-metal (Al/Cu) reducer lugs?

Standard configurations ship in 7 days, while custom Cu-Al transitions require 14 days for plating validation. Rush service (72 hours) is available for emergency, with prototype test reports provided before full production.

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LOCATIONS

Sitz

10-A, First Floor, V. V Komplex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, Indien.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti Coimbatore-641035, Tamil Nadu, Indien. ㅤ

Reducer-Type Aluminum Lugs

Material Composition

Conductor Size Range

Current Carrying Capacity

Dimensions

Weight

Product Description

Barrel Length

Termination Type

Crimping Compatibility

Operating Temperature Range

Surface Finish

Voltage Rating

Tensile Strength

Environmental Resistance

Standards Compliance

Installation Method

Conductor Compatibility

Technical Advantages

Let's Get Started

Industry Applications

Seamless Current Transition for Mixed-Conductor Systems

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Having Doubts? Our FAQ

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Reducer-Type Aluminum Lugs

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Reducer-Type Aluminum Lugs

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