Copper TipsIn order to connect a home appliance or appliance to the electrical network, it is not enough to get an electrical wire into this device, you still need to take care of good contact. In case of unreliable contact, the device may experience overloads, which, in turn, will lead to its breakage.

To ensure reliable contact of equipment with an electric cable, special tips are used with which to terminate an electric wire. The material from which the cable ends are made may be different, but copper is considered the most reliable and proven. Copper contacts appreciate for tightness. They are immune to aggressive media.


  • 1 Copper cable lugs: general information
    • 1.1 Types and types
    • 1.2 Marking
    • 1.3 Copper tinned cable lugs with viewing window
    • 1.4 Homemade Copper Cable Lugs
  • 2 Mounting copper cable lugs

Copper cable lugs: general information

Copper cable lugs for pressure testing are made of copper pipes of a certain diameter. Pipes are cut and flattened on one side. In the flattened part of the hole is made of a certain diameter for the bolt. Produced in special enterprises.

Types and types

Cable copper contacts are of two types:

  • cable lugs without coating;
  • tips with a tinned covering.

Tin-plated contacts are considered more practical to use. Tin-plated coating protects the tip from corrosion and prolongs its life. In addition, tinned contacts are resistant to solutions of nitric, sulfuric and hydrochloric acid. They are not afraid of exposure to air, moisture and other aggressive media. Due to the coating, the electrical conductivity of the tips is reduced. However, it consistently holds excellent performance.

But the copper contacts, deprived of the coating, oxidize very quickly, because of which the conductivity index decreases and the resistance increases, which will lead to heating of the connection.

Tips serve for cable termination with copper veins. For their installation are usually used special press tongs, which crimp the terminal on the cable.

Copper cable lugs are used under pressure testing for:

  • installation of communication between the power supply network and the device;
  • establishing contact between devices or a group of devices;
  • splicing multiple electrical wires to increase length.


To distinguish the types of tinned copper contacts there is a special marking - combination of certain letters and numbers:

  • Examples of cable lugsT - tip made of a tube;
  • M - the name of the material is copper (if the tip is aluminum, then there will be a boom ā€œAā€, if it is brass - ā€œLā€;
  • L-contact service;
  • Y is an angular model.

After the lettering in the marking usually comes digital, in which you can find information about:

  1. nominal section;
  2. the diameter of the contact rod;
  3. the inner diameter of the shank.

Copper tinned cable lugs with viewing window

Have the abbreviation TML (o), from which it follows that these cable ends are made of copper tube and tinned. Their distinctive feature is the presence of a small hole - a viewing window. With it, you can make sure that the cable is correctly inserted into the lug. Such contacts are mainly used in production, so not all electricians know about their existence.

Homemade Copper Cable Lugs

Today, manufacturers offer a choice of many varieties of cable copper terminals for crimping. However, there are situations when it is impossible to pick up the cable tip of the desired size. In this case, you can use a non-standard option - make the tip yourself.

The manufacturing process is not difficult. To do this, take a copper tube of a certain size, flatten one end and make a hole of the desired diameter.

However, it remains an open question what allowable loads this handicraft product can withstand. Therefore, you should not use such a terminal in the responsible nodes of the power grid.

Mounting copper cable lugs

Tinned tips can be installed on the cable in the following ways:

  1. Cable lugsThe method of crimping.
  2. Screw or bolt method (for the way you need a screw or bolt).
  3. Welded way.
  4. Soldering method.

The fastest and most reliable way terminate cable is crimping. When it comes to cable termination at home, hand presses are usually used for this. But to terminate the power cable you need to use more effort. For such an operation, a hydraulic or mechanical press will be suitable.

Crimping is as follows, the end of the cable is stripped of insulation and inserted into the cable end, which is squeezed by press jaws. It is important to choose the hole in the tongs correctly, otherwise the conductors may break off. Pliers have holes from 0.25 mm. up to 1 mm. To remove the insulation from the cable, it is best to use a shear tool or machine.

For crimping is not recommended to use the pliers. First, it will not be possible to press the tip tightly. Secondly, in the process of crimping, the cable can slip out of the end, because to work with the pliers use two hands, while controlling with the press tongs, this does not happen - with one hand hold the wire and the other compress the tongs.

In the screw version of the wire is fixed in the tip with a screw. And for the application of the welded method or the method of soldering will have to use the appropriate device - welding or soldering iron.