Solar-Grade Bimetallic Lugs

Name: Solar-Grade Bimetallic Lugs | Solar Panel Cable Lugs | PV Bimetal Cable Lugs - Frigate
Price: 249.00 USD
Availability: InStock

In solar installations, conventional lugs create three critical pain points which are DC arcing risks at high voltages, corrosion from PID effects, and incompatible terminations between copper PV wires and aluminum array cables. Our Solar-Grade Bimetallic Lugs solve these challenges with precision-engineered copper-aluminum transitions that outperform standard connectors in both safety and longevity.

Material Composition

Oxygen-free copper (C10200) barrel + Aluminum 6101-T6 tongue with explosion-welded transition zone

Conductor Size Range

25 mm² to 400 mm² (PV wire: 10 AWG to 600 kcmil)

Current Carrying Capacity

80 A to 1200 A (DC, 40°C ambient) with 1.25× safety factor

Dimensions

Barrel OD: 12-50 mm; Tongue width: 15-45 mm; Bolt holes: M8-M20 (tinned)

Weight

40 g to 900 g (optimized for rooftop loading)

Product Description

The explosion-welded interface maintains ≤0.2mV contact potential even after 3000 thermal cycles (-40°C to +120°C), while the silver-anodized finish provides dual protection against PID and UV degradation. These lugs are 35% lighter than full-copper alternatives, reducing structural loading on rooftop PV systems without compromising 1500V DC performance.

Barrel Length

30-60 mm (copper side) / 35-65 mm (aluminum side)

Termination Type

Dual-compression barrel with UV-resistant EPDM insulation collar

Crimping Compatibility

Hexagonal dies (copper) + 4-point solar crimpers (aluminum), 25-80 kN

Operating Temperature Range

-40°C to +90°C continuous (+120°C peak, 2hr/day)

Surface Finish

Silver-plated copper (8-12μm) + Anodized aluminum (20-25μm)

Voltage Rating

1500V DC (UL 6703/IEC 62852 compliant)

Tensile Strength

220 MPa at transition zone (EN 50565-1 tested)

Environmental Resistance

UV stability (3000 kWh/m²), 85% RH damp heat (IEC 61215), -40°C thermal cycling

Standards Compliance

UL 486B, IEC 61238-1 Class A/B, TÜV Rheinland 2PfG 2511

Installation Method

Sequential crimping (copper first) with 1.5-25 Nm torque for combiner boxes

Conductor Compatibility

PV wire (UL 4703), USE-2 (UL 854), aluminum alloy (EN 50618)

Technical Advantages

The silver-plated copper barrel delivers 100% IACS conductivity while the anodized aluminum tongue provides 60% weight savings. Explosion welding creates a 220MPa bond at the transition zone which strong enough to withstand 10G vibration in tracker systems.

Third-party testing verifies 0.5% annual resistance change through 10-year accelerated aging. The integrated EPDM collar blocks 99% of UV radiation, extending service life beyond standard lugs by 3x in outdoor exposure.

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

Utility-Scale Solar Farms

Withstands 1500V DC string voltages and 1200A combiner box currents, complying with NEC 690.11 arc-fault requirements.

Commercial Rooftop Arrays

Lightweight design (900g max) prevents roof stress while the compact barrel fits tight combiner box spaces.

Floating Solar Installations

Marine-grade anodization withstands constant humidity and water exposure, passing 3000-hour salt spray tests.

Tracking System Connections

Flex-rated transition zone endures daily 200° panel rotations without fatigue.

Agri-PV Configurations

Chemical-resistant coating prevents corrosion from fertilizers while maintaining UL 4703 compliance for direct burial.

Harsh Environment Systems

Dual-certified (IEC 61215/TÜV 2PfG 2511) for desert heat (+80°C), alpine cold (-40°C), and coastal salinity.

Streamlined Solar Deployment

Installers benefit from color-coded collars (orange=25mm², blue=50mm²) and torque-limited hardware (1.5-25Nm) that prevent over-tightening. Each lug ships with dual crimp guides for PV wire (hexagonal die) and aluminum cable (4-point solar crimper).

Project managers receive complete documentation packs including UL 486B reports, PID test data, and 1500V DC certification. Custom kits with pre-installed MC4 connectors are available for plug-and-play string connections.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does the explosion-welded transition handle daily thermal cycling in solar farms?

The copper-aluminum interface maintains stable conductivity through 3000+ thermal cycles (-40°C to +120°C), with independent testing showing <0.5% resistance change annually. The nickel-chromium barrier layer prevents intermetallic diffusion even in desert environments with 50°C daily swings. This outperforms mechanical joints by 8x in accelerated aging tests per IEC 61215.

What prevents PID (Potential Induced Degradation) in these lugs?

The 25μm anodized aluminum tongue acts as a dielectric barrier, tested to <2% power loss after 1000 hours at -1000V bias per IEC 62804. Silver-plated copper contacts pflegen <0.2mV potential difference, eliminating ionic migration risks. Optional insulation collars provide additional protection for systems exceeding 1500V.

Are special tools required for field installations?

Standard solar crimpers (Klauke, Weidmüller) with 4-point dies (25-80kN) work for aluminum sides, while hexagonal dies handle copper terminations. Color-coded lug markings (red=Cu, blue=Al) and included torque specs (1.5-25Nm) prevent installation errors. Training videos are accessible via QR codes on each lug.

How do you verify 1500V DC safety for NEC 690.11 compliance?

Third-party labs validate 1500V DC withstand voltage (IEC 62852) and 20kA arc-fault interruption. Partial discharge tests confirm <5pC at 1.5Ur, with full reports included in certification packages. Our lugs exceed 1000-hour damp heat testing at 85% RH and 85°C.

Can these lugs integrate with solar monitoring systems?

Optional smart versions embed IoT current sensors (±1% accuracy) that transmit via Bluetooth to SCADA systems. The sensors withstand 10G vibration and 1500V isolation, with 5-year battery life. Data includes temperature, current flow, and connection resistance trends.

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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

Solar-Grade Bimetallic 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

Streamlined Solar Deployment

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Having Doubts? Our FAQ

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LOCATIONS

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Operations Office

Weitere Standorte

ALLGEMEINE ANFRAGEN

Funktionen

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Solar-Grade Bimetallic Lugs

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Solar-Grade Bimetallic Lugs

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