earth lugs
TRANSCRIPT
PIONEER ALUMINIUM ALLOY TUBULAR BIMETALLIC TERMINALS
Pioneer AluminiumAlloy Tubular Bi-metallicTerminalsare manufactured outofaluminiumof purity equal toorgreaterthan 99.5% having maximum conductivity not less than 60% IACS and are designed as per IS 5082. These are anti-corrosive and used for highly corrosive environment. The barrels are kept filled with grease so as to avoid oxidization of the Aluminium. These are designed to accept a variety of conductor forms especially low stranded compacted conductors. These terminals are mainly used to terminate on copper bus bars. Whenever aluminium links terminated on to copper or copper based alloy terminals without suitable plating, results in the corrossion of the joint overa period leading to higher joint resistance. Bi-metallic terminals are found most reliableand suitable forsuch connections.
Material: Aluminium IS: 5082
Size Sq. mm
10
16
25
35
50
70
95
120
E
6
8
6
8
8
10
8
10
8
10
10
12
10
12
10
12
A
4.4
4.4
5.4
5.4
7.0
7.0
8.0
8.0
9.3
9.3
11.6
11.6
12.9
12.9
14.8
14.8
Dimensions
C D
7.4
7.4
8.3
8.3
10.0
10.0
10.8
10.8
13.0
13.0
16.0
16.0
17.1
17.1
19.6
19.6
10
15
11
11
14
20
15
20
18
23
22
22
25
25
28
28
B
9
9
13
13
16
16
18
18
22
22
26
26
28
28
32
32
J
30
30
37
37
44
44
47
47
54
54
60
60
64
64
73
73
Code No.
ATB-1
ATB-2
ATB-3
ATB-4
ATB-5
ATB-6
ATB-7
ATB-8
ATB-9
ATB-10
ATB-11
ATB-12
ATB-13
ATB -14
ATB-15
ATB-16
Size Sq. mm
150
185
225
240
300
400
500
630
800
1000
E
12
16
12
16
12
12
16
16
20
20
20
20
A
16.1
16.1
18.0
18.0
20.6
22.0
22.0
24.0
24.0
28.0
30.0
35.0
39.0
43.5
Dimensions
C
21.2
21.2
23.7
23.7
27.0
28.0
28.0
31.0
31.0
36.0
41.0
46.0
51.0
57.0
D
31.0
31.0
34.0
34.0
39.0
40.0
40.0
45.7
45.7
51.0
58.0
66.0
73.0
81.0
B
34
34
36
36
40
44
44
47
47
56
60
69
77
100
J
79
79
84
84
94
102
102
115
115
130
140
154
180
220
Code No.
ATB-17
ATB-18
ATB-19
ATB - 20
ATB - 21
ATB - 22
ATB - 23
ATB - 24
ATB - 25
ATB - 26
ATB - 27
ATB - 28
ATB - 29
ATB - 30
PIONEER ALUMINIUM CRIMPING CONNECTORS
Pioneer Aluminium Crimping In-Line Connectors are made out of extrusion tubes of purity equal to or greater than 99.5% having maximum conductivity not less than 60% IACS and are designed as per IS 5082. These connectors facilitate joining two identical size Aluminium conductors.
Material: Al
Size Sq. mm
2.5
4
6
10
16
25
35
50
70
95
120
150
185
225
240
300
400
500
630
800
1000
uminium IS:
A
2.0
2.6
2.9
3.5
4.4
3.8
5.4
7.0
8.0
9.3
11.6
12.9
14.8
16.1
18.0
20.6
22.0
24.0
28.0
30.0
35.0
39.0
43.5
5082
Dimensions
C
5.5
5.5
5.5
5.5
7.4
6.2
8.3
10.0
10.8
13.0
16.0
17.1
19.6
21.2
23.7
27.0
28.0
31.0
36.0
41.0
46.0
51.0
57.0
J
16
16
16
16
20
20
26
35
40
45
55
60
65
70
75
85
90
100
115
125
140
160
210
Code No.
ILA-145
ILA-6
ILA-5
ILA-13
ILA-14
ILA-146
ILA-4
ILA-3
ILA-2
ILA-12
ILA-1
ILA-15
ILA-9
ILA-10
ILA-11
ILA-147
ILA-16
ILA-17
ILA-18
ILA-19
ILA-20
ILA-148
ILA-149
PIONEER ALUMINIUM CRIMPING REDUCER TERMINALS FOR ALUMINIUM CONDUCTOR
Pioneer Aluminium Reducer Terminals are manufactured out of aluminium of purity equal to or greater than 99.5 % having maximum conductivity not less than 60% IACS and are designed as per IS 5082. These are used to terminate one or more Aluminium conductors to asmallertermination area.Pioneer is able to produce anyAluminium Reducing Linkthat you may require.
Material: Aluminium IS: 5082
Size Sq. mm
2.5
4
6
10
16
25
35 50
70
A
2.6 2.6 2.9
2.9 3.5 3.5 3.8 3.8 4.4 4.4 5.4 5.4 5.4
7 7
8 9.3
10.4
11.6
11.6
11.6
c
5.5 5.5 5.5 5.5 5.5 5.5 7.4 7.4 7.4 7.4 8.3 8.3
8.3 10 10
10.8
13 14
16.0
16.0
16.0
Dimensions
D D-1
4.5 3.5 4.5 3.8 4.5 3.8 4.5 3.8 4.5 3.8 6.0 6.0 3.8
6.0 7.5 7.5 7.5 14
7.5 11.5
11.5
4
3.3 4
3.3 4
3.3 4
3.3 4
3.3 5.5 5.5
3.3 5.5 6.5 6.5 6.5 13 6.5
10.5
10.5
B
9 9 9 9
13 13
13 16 16 18 22 22
26 26 26
J
21 21 21 21
21 21 23 23 23 23 33 38
31 36 41
43 47
53 51 56 63
Code No.
WPA-1
WPA-7
WPA-15
WPA-16
WPA-17
WPA-18
WPA-19
WPA-20
WPA-21
WPA-22
WPA-23
WPA-24
WPA-2
WPA-25
WPA-3
WPA-4
WPA-26
WPA-5
WPA-27
WPA-6
WPA-28
Size Sq. mm
95
120
150
185
225
240
300
A
12.9
12.9
12.9
12.9
14.8
14.8
14.8
14.8
16.1
16.1
18.0
18.0
20.6
20.6
20.6
22.0
22.0
24.0
24.0
C
17.1
17.1
17.1
17.1
19.6
19.6
19.6
19.6
21.2
21.2
23.7
23.7
27.0
27.0
27.0
28.0
28.0
31.0
31.0
Dimensions
D D-1
11.5
15.6
7.5
12.8
11.5
7.5
11.5
15.6
15.6
15.6
15.6
11.5
15.6
21.0
16.0
16.0
15.6
16.0
15.6
10.5
14.0
6.5
11.8
10.5
6.5
10.5
14.0
14.0
14.0
14.0
10.5
14.0
18.0
15.0
15.0
14.0
15.0
14.0
B
28
28
28
28
32
32
32
32
34
34
36
36
40
40
40
44
44
47
47
J
59
61
56
66
63
60
70
70
72
72
74
74
80
90
90
94
84
94
84
Code No.
WPA-29
WPA-8
WPA-31
WPA-32
WPA-33
WPA-34
WPA-35
WPA-36
WPA-10
WPA-37
WPA-30
WPA-38
WPA-39
WPA-46
WPA-42
WPA-44
WPA-43
WPA-45
WPA-47
PIONEER ALUMINIUM CRIMPING TERMINALS
Pioneer Aluminium Crimping Terminals are manufactured out of tubes of purity equal to or greaterthan 99.5%, having maximum conductivity not less than 60% IACS and are designed as per IS 5082. These are used for terminating all sizes of cables to terminate electrical switching equipments. The absence of an inspection hole prevents the entry of wateror moisture into crimped joints making them suitable for outdoorapplications.
Material: Aluminium IS: 5082
Size Sq. m m
2.5
4
6
10
16
25
35
50
70
E
3.2
3.7
4.2
5.2
5.2
6.4
6.4
8.2
6.4
8.2
10.2
6.4
8.2
10.2
12.7
6.4
8.2
10.2
8.2
10.2
12.7
8.2
10.2
12.7
A
2.0
2.6
2.9
2.9
3.5
3.5
4.4
4.4
5.4
5.4
5.4
7.0
7.0
7.0
7.0
8.0
8.0
8.0
9.3
9.3
9.3
11.6
11.6
11.6
Dimensions
C D
5.5
5.5
5.5
5.5
5.5
5.5
7.4
7.4
8.3
8.3
8.3
10.0
10.0
10.0
10.0
10.8
10.8
10.8
13.0
13.0
13.0
16.0
16.0
16.0
7
7
7
12
8
12
10
15
11
11
18
14
14
20
20
15
15
20
18
23
23
22
22
22
B
9
9
13
13
13
16
16
16
16
18
18
18
22
22
22
26
26
26
J
18
18
18
24
24
24
30
30
37
37
37
44
44
44
44
47
47
47
54
54
54
60
60
60
Code No.
AT-151
AT-309
AT-155
AT-317
AT-158
AT-313
AT-214
AT-215
AT-252
AT-216
AT-217
AT-253
AT-218
AT-219
AT-220
AT-254
AT-221
AT-222
AT-255
AT-312
AT-224
AT-256
AT-225
AT-226
size Sq. m m
95
120
150
185
225
240
300
400
500
630
800
1000
Dimensions
E A C D B J
10.2
12.7
16.2
10.2
12.7
16.2
10.2
12.7
16.2
10.2
12.7
16.2
12.7
12.7
16.2
20.0
16.2
20.3
20.3
20.3
20.3
12.9
12.9
12.9
14.8
14.8
14.8
16.1
16.1
16.1
18.0
18.0
18.0
20.6
22.0
22.0
22.0
24.0
24.0
28.0
30.0
35.0
39.0
43.5
17.1
17.1
17.1
19.6
19.6
19.6
21.2
21.2
21.2
23.7
23.7
23.7
27.0
28.0
28.0
28.0
31.0
31.0
36.0
41.0
46.0
51.0
57.0
25.0
25.0
25.0
28.0
28.0
28.0
31.0
31.0
31.0
34.0
34.0
34.0
39.0
40.0
40.0
40.0
45.7
45.7
51.0
58.0
66.0
73.0
81.0
28
28
28
32
32
32
34
34
34
36
36
36
40
44
44
44
47
47
56
60
69
77
100
64
64
64
73
73
73
79
79
79
84
84
84
94
102
102
102
115
115
130
140
154
180
220
Code No.
AT-227
AT-228
AT-229
AT-257
AT-230
AT-231
AT-258
AT-232
AT-233
AT-311
AT-234
AT-235
AT-320
AT-236
AT-237
AT-238
AT-300
AT-259
AT-260
AT-296
AT-261
AT-318
AT-319
PIONEER ALUMINIUM TUBE TERMINALS FOR AL-XLPE CONDUCTOR
Pioneer AT-XLtypeof terminals are manufactured out of extrusion tubes of purity equal toorgreaterthan 99.5% having maximum conductivity not less than 60% lACSand are designed as perAluminium IS 5082 suitable for high voltage application where termination of XLPE cable is required.
Material: Aluminium IS: 5082
Size Sq. m m
25
35
50
70
95
120
150
185
225
240
300
400
500
630
800
1000
Dimensions
E A C D B G+H J
8.2
8.2
10.2
10.2
12.7
12.7
12.7
12.7
12.7
12.7
20.3
20.3
20.3
20.3
20.3
20.3
7.2
8.3
10.1
10.2
12.0
13.7
15.1
16.6
18.6
19.3
21.8
25.0
28.2
31.7
35.7
41.0
9.6
11.1
13.5
14.5
16.6
19.0
21.1
23.9
26.1
27.2
30.2
34.8
39.1
44.4
49.5
56.0
14
16
19.5
20.5
23.5
26.5
29.5
33.0
36.0
37.5
42.0
48.0
54.0
61.0
68.0
77.5
41
50
49
62
73
73
83
83
86
86
89
113
125
140
147
160
21
22
24
26
28
30
34
36
40
44
54
60
64
68
78
90
69
79
81
96
109
114
128
131
140
144
157
187
205
225
250
280
Code No.
AT-XL 17
AT-XL 18
AT-XL 19
AT-XL 20
AT-XL 21
AT-XL 22
AT-XL 23
AT-XL 24
AT-XL 25
AT-XL 26
AT-XL 27
AT-XL 28
AT-XL 29
AT-XL 30
AT-XL 31
AT-XL 32
PIONEER BI-METALLIC PIN TERMINALS
Pioneer Bl-metalllc Connectors are made from aluminium purity equal to orgreaterthan 99.5 %. The barrel is friction welded to the pin thus achieving the best possible transition between the copper pin and aluminium barrel. Barrels are capped and filled with grease so as to avoid oxidisation of the aluminium.
Material: Aluminium 99.5; E Copper Surface: Bright
Size Sq.mm.
16
25
35
50
70
95
120
150
185
240
A
5.5
6.5
8.0
9.0
11.0
12.5
13.7
15.5
17.0
19.5
C
16
16
16
20
20
20
25
25
32
32
DIMENSIONS
D-1 P
8
8
8
12
12
12
14
14
14
14
30
30
30
45
45
45
55
55
55
55
J
82
82
82
97
97
97
125
125
125
125
CAT NO.
CAP-16
CAP-25
CAP-35
CAP-50
CAP-70
CAP-95
CAP120
CAP-150
CAP-185
CAP-240
PIONEER BI-METALLIC TERMINALS
Pioneer Bi-metallic terminals for aluminium conductors are manufactured from solid materials by friction welding. This method means that aluminium and Copper join through the heat, which develops when aluminium rotates against copper under pressure. This is a superior method to give a complete connection between Aluminium and Copper. Barrels are caped and filled with grease so as to avoid oxidisation of the aluminium.
Material: Aluminium 99.5, E Copper Surface: Bright
Size Sq.mm.
16
25
35
50
70
95
120
150
185
240
300
E
13
13
13
13
13
13
13
13
13
13
13
A
5.5
6.5
8.0
9.0
11.0
12.5
13.7
15.5
17.0
19.5
22.5
Dimension
C D
16
16
16
20
20
20
25
25
32
32
34
24
24
24
24
24
24
31
31
35
35
35
J
87
87
87
87
87
87
111
111
116
116
120
CAT NO.
CAT-16
CAT-25
CAT-35
CAT-50
CAT-70
CAT-95
CAT-120
CAT-150
CAT-185
CAT-240
CAT-300
PIONEER CORROSION INHABITING COMPOUND Pioneer Corrosion Inhabiting Compound is recommended for crimping connections. It is suggested where conditions are particularly aggressive such as chemical or salt-laden atmospheres or where inspection and cleaning are not regular.
Pioneer Corrosion Inhabiting Compound is a mixture of Grey Lithium based grease with abrasive particles and suspended Zinc particles, which assist in jointing because as metal flows under pressure the abrasive particles cause small area of cold welding:
• Corrosion Inhibitordoesnotaffecttheelectricalpropertiesofthecompression joint.
• It is non-corrosive to aluminium, copper, steel, tin, zincand combination of these metals.
' ltdoes not deteriorate on exposuretoatmosphereatconductoroperatingtemperature.
• It has good sealing properties against moisture and contaminating substances in the atmosphere It has high temperature drop point.
The mixture contains:
1. Grey Lithium based grease 85% 2. ZincChromate 5% 3. Titanium Dioxide 10%
Test Report
The test carried out on 200 mm conductor joined with Aluminium lugs 95 Sq. mm. The test tesults found in terms of mV drop compared to joint with nonuse of compound, joint with Pioneer Compound and joint with imported compound
Specification
At 700 Amp at Ambient Temp.
At 700 Amp after 1/2 hour ageing at 90°C
After 10 days at 90°C
After 1/2 hour ageing at 200°C after 2nd test
Joint without
Compound
4.42 mV
5.70 mV
6.16 mV
7.06 mV
Joint wi th Pioneer
Compound
2.65 mV
2.97 mV
3.1 mV
3.55 mV
Joint with Imported
Compound
3.85 mV
4.75 mV
5.35 mV
5.56 mV
PIONEER COPPER CRIMPING REDUCER TERMINALS FOR ALUMINIUM CONDUCTOR Pioneer Copper Crimping Reducer Terminals are used to terminate one or more Aluminium conductors to a smaller termination area. These type of terminals are applicable in tunnel type terminal blocks viz. fuse gears, cut-outs, meters etc. Pioneer is able to produce any Copper Reducing Linkthat you may require. The presence of copper at termination end ensures high current carrying capacity at smaller surface area. Tinning avoids oxidisation and provides maximum corrosion protection.
Material: Copper BS1977 Finish: Electro Tinned
Size Sq. mm
2.5
4
6
10
16
25
35
50
Dimensions
A C D D-1 B J
2.5
2.5
2.8
2.8
3.1
3.1
3.8
3.8
4.4
4.4
5.3
5.3
5.3
7.0
7.0
8.0
9.2
10.4
4.7
4.7
4.7
4.7
4.7
4.7
5.5
5.5
6.2
6.2
7.1
7.1
7.1
9.0
9.0
10.0
11.2
14.0
4.5
3.8
4.5
3.8
4.5
3.8
4.5
3.8
4.5
3.8
6.0
6.0
3.8
6.0
7.5
7.5
7.5
14.0
4.0
3.3
4.0
3.3
4.0
3.3
4.0
3.3
4.0
3.3
5.5
5.5
3.3
5.5
6.5
6.5
6.5
13.0
6
6
6
6
6
6
9
9
9
9
12
12
12
12
12
12
16
18
20
20
20
20
20
20
23
23
23
23
32
37
30
32
37
37
41
49
Code No.
WPC- 1
WPC- 7
WPC-15
WPC-16
WPC-17
WPC-18
WPC-19
WPC-20
WPC-21
WPC-22
WPC-23
WPC-24
WPC- 2
WPC-25
WPC- 3
WPC- 4
WPC-26
WPC- 5
Size
Sq. mm
70
95
120
150
185
225
240
300
400
Dimens ions
A C D D-1 B J
11.5
11.5
11.5
12.8
12.8
12.8
14.8
14.8
16.0
16.0
18.0
18.0
20.0
22.0
22.0
24.0
24.0
27.0
13.8
13.8
13.8
15.6
15.6
15.6
17.8
17.8
19.6
19.6
22.0
22.0
26.0
26.0
26.0
28.7
28.7
33.2
7.5
11.5
11.5
11.5
7.5
12.8
7.5
11.5
15.6
11.5
15.6
11.5
15.6
16.0
16.0
16.0
16.0
16.0
6.5
10.5
10.5
10.5
6.5
11.8
6.5
10.5
14.0
10.5
14.0
10.5
14.0
15.0
14.0
15.0
14.0
14.0
18
18
18
20
20
20
22
22
26
26
32
32
38
38
38
42
42
46
43
48
55
51
48
58
50
60
64
64
70
70
78
88
78
92
82
90
Code No.
WPC-27
WPC- 6
WPC-28
WPC-29
WPC-31
WPC-32
WPC-34
WPC-35
WPC-10
WPC-37
WPC-30
WPC-38
WPC-39
WPC-44
WPC-43
WPC-45
WPC-47
WPC-101
COPPER CRIMPING TERMINALS WITH INSPECTION HOLE (LIGHT DUTY)
Pioneer Copper Tube Crimping Terminals With Inspection Hole are manufactured from Electrolytic Copper tube. The dimensions of the tube are designed to obtain the most efficient electrical conductivity and mechanical strength to resist vibration and pull out. These are used for terminating any size of cables, electrical switching equipments, where vibration is critical.
Terminals are annealed to guarantee optimum ductility which is an absolute necessity for connectors which will have to withstand the sever deformation arising when compressed and any bending of the palm during installation. In application subject to vibration, terminals still have to performareliabieconnection, annealing playsa vital role in avoiding cracking orbreaks between the barrel and palm.
The presence of inspection hole facilitates full insertion of conductor while the barrel length has been designed to allow easy and accurate position dies during the crimping operation.
Tin plating on the terminals avoids oxidization and achieves maximum corrosion protection.
Material Copper BS: 1977 Finish: Electro Tinned
Size Sq. mm
35
50
70
95
E
6.4
8.4
10.5
13
6.4
8.4
10.5
13
6.4
8.4
10.5
13
8.4
10.5
13
A
8.0
8.0
8.0
8.0
9.2
9.2
9.2
9.2
11.6
11.6
11.6
11.6
12.8
12.8
12.8
Dimensions
C D
10.0
10.0
10.0
10.0
11.2
11.2
11.2
11.2
13.8
13.8
13.8
13.8
15.6
15.6
15.6
17
17
17
17
20
20
20
20
20
20
20
20
22
22
22
B
15
15
15
15
16
16
16
16
20
20
20
20
23
23
23
J
40
40
40
40
49
49
49
49
58
58
58
58
60
60
60
Code No.
CA-35/6
CA-35/8
CA-35/10
CA-35/12
CA-50/6
CA-50/8
CA-50/10
CA-50/12
CA-70/6
CA-70/8
CA-70/10
CA-70/12
CA-95/8
CA-95/10
CA-95/12
Size Sq. mm
120
150
185
240
300
400
500
630
800
1000
E
8.4
10.5
13
17
10.5
13
17
10.5
13
17
13
17
21
17
21
17
21
17
21
21
A
14.8
14.8
14.8
14.8
16.0
16.0
16.0
18.0
18.0
18.0
22.0
22.0
22.0
24.0
24.0
28.0
28.0
30.0
30.0
35.0
39.0
43.0
Dimensions
C D
17.8
17.8
17.8
17.8
19.6
19.6
19.6
22.0
22.0
22.0
26.0
26.0
26.0
28.7
28.7
33.2
33.2
36.0
36.0
41.5
46.3
53.8
25.5
25.5
25.5
25.5
29.0
29.0
29.0
34.5
34.5
34.5
41.0
41.0
41.0
43.5
43.5
47.0
47.0
54.0
54.0
63.0
80.0
100.0
B
26
26
26
26
28
28
28
32
32
32
38
38
38
42
42
49
49
53
53
61
67
76
J
65.5
65.5
65.5
65.5
73
73
73
86.5
86.5
86.5
102
102
102
107
107
119
119
126
126
145
170
205
Code No.
CA-120/8
CA-120/10
CA-120/12
CA-120/16
CA-150/10
CA-150/12
CA-150/16
CA-185/10
CA-185/12
CA-185/16
CA-240/12
CA-240/16
CA-240/20
CA-300/16
CA-300/20
CA-400/16
CA-400/20
CA-500/16
CA-500/20
CA-630/20
CA-800/BL
CA-1000/BL
COPPER CRIMPING TERMINALS WITH INSPECTION HOLE FOR COPPER CONDUCTOR (HEAVY DUTY)
Pioneer Copper Tube Crimping Terminals are manufactured from Electrolytic Copper tube. The dimensions of the tube are designed to obtain the most efficient electrical conductivity and mechanical strength to resist vibration and pull out. These are used forterminating any size of cables, electrical switching equipments, where vibration is critical.
Terminals are annealed to guarantee optimum ductility which is an absolute necessity for connectors which will have to withstand the sever deformation arising when compressed and any bending of the palm during installation. In application subjectto vibration, terminals still have to perform a reliable connection, annealing plays a vital role in avoiding cracking or breaks between the barrel and palm.
The presence of inspection hole facilitates full insertion of conductorwhile the barrel length has been designed to allow easy andaccurate position diesduring the crimping operation.
Tin plating on the terminals avoids oxidization and achieves maximum corrosion protection
Material Copper BS: 1977 Finish: Electro Tinned
Size Sq. mm
1.5
2.5
4
6
10
E
4.2 5.2 6.4 4.2 5.2 6.5 8.4 4.2 5.2 6.5 8.4 5.2 6.5 8.4
10.5
5.2 6.5 8.4
10.5 12.7
A
1.8 1.8 1.8 2.4 2.4 2.4 2.4 3.1 3.1 3.1 3.1 3.8 3.8 3.8 3.8 4.5 4.5 4.5 4.7 4.7
Dimensions
C D
3.7 3.7 3.7 4.0 4.0 4.0 4.0 4.8 4.8 4.8 4.8 5.5 5.5 5.5 5.5 6.2 6.2 6.2 7.1 7.1
8 8
10 8
10 10
11.5
10 10 10
11.5
10 12 12 15 12 12 12 14 18
B
5 5 5
9 9 9 9 9 9 9
10 10
J
16 16 18 18 20 20 24 20 20 20 25 23 27 27 32 25 25 27 32 32
Code No.
CT-711
CT-538
CT-539
CT-388
CT-540
CT-541
CT-762
CT-564
CT-389
CT-543
CT-763
CT-390 CT-544
CT-545 CT-854
CT-822
CT-353
CT-547
CT-855
CT-856
Size Sq. mm
16
25
35
50
70
E
5.2 6.4 8.4
10.5
12.7
6.4 8.4
10.5
12.7
6.5 8.4
10.5
12.7
6.5 8.4
10.5 12.7
17.0 6.4 8.4
10.5
13.0
15.0
17.0
21.0
A
5.4 5.4 5.4 5.5 5.5 6.8 6.8 6.8 6.8 8.2 8.2 8.2 8.2 9.5 9.5 9.5 9.5 9.5
11.2
11.2
11.2
11.2
11.2
11.2
11.2
Dimensions
C D
7.1 7.1 7.1 7.9 7.9 8.8 8.8 8.8 8.8
10.6
10.6
10.6
10.6
12.4
12.4
12.4
12.4
12.4
14.7
14.7
14.7
14.7
14.7
14.7
14.7
12 12 12
14.5
18 13 16 16
16.5
15.3
15.3
18 17 18 18 18 18
22.0
21.0
21.0
21.0
21.0
25.0
25.0
26.0
B
12 12 12 13 13 12 12 12 14 12 12 12 15 16 16 16 16 18 18 18 18 18 20 20 20
J
30 30 32 35 39 30 37 35 40 35 35 38 42 43 43 43 43 52 50 50 50 50 55 55 55
Code No.
CT-696
CT-354
CT-549 CT-657
CT-858
CT-355
CT-551 CT-552
CT-765
CT-542
CT-356
CT-554
CT-853
CT-746
CT-357
CT-556
CT-698
CT-699
CT-748 CT-557
CT-358
CT-559
CT-795
CT-780
CT-781
Size Sq. mm
95
120
150
185
E
8.4
10.5
13.0
15.0
17.0
21.0
8.5
10.5
12.7
15.0
17.0
21.0
8.4
10.5
12.7
15.0
17.0
21.0
10.5
12.7
15.0
17.0
21.0
Dimensions
A
13.5
13.5
13.5
13.5
13.5
13.5
15.0
15.0
15.0
15.0
15.0
15.0
16.5
16.5
16.5
16.5
16.5
16.5
18.5
18.5
18.5
18.5
18.5
c
17.4
17.4
17.4
17.4
17.4
17.4
19.4
19.4
19.4
19.4
19.4
19.4
21.2
21.2
21.2
21.2
21.2
21.2
23.5
23.5
23.5
23.5
23.5
D
25
25
25
26
26
28
28
28
28
28
28
28
30
30
30
30
30
30
34
34
34
34
34
B
20
20
20
20
22
22
22
22
22
22
22
22
26
26
26
26
26
26
32
32
32
32
32
J
55
55
55
55
60
60
64
64
64
64
64
64
69
69
69
69
69
69
78
78
78
78
78
Code No.
CT-752
CT-359
CT-561
CT-796
CT-672
CT-673
CT-782
CT-700
CT-241
CT-797
CT-546
CT-798
CT-783
CT-676
CT-242
CT-799
CT-564
CT-565
CT-652
CT-639
CT-800
CT-243
CT-704
Size Sq. mm
240
300
400
500
630
800
1000
E
10.5
12.7
15.0
17.0
21.0
10.5
12.7
15.0
17.0
21.0
17.0
21.0
17.0
21.0
17.0
21.0
21.0
21.0
A
21
21
21
21
21
23.5
23.5
23.5
23.5
23.5
26.8
26.8
30
30
35
35
35
39
39
43
43
c
26.5
26.5
26.5
26.5
26.5
30
30
30
30
30
34.8
34.8
39
39
45
45
45
50.6
50.6
56.2
56.2
Dimensions
D
38
38
38
38
38
43
43
43
43
43
50
50
56
56
65
65
65
72.9
72.9
80.8
80.8
B
38
38
38
38
38
42
42
42
42
42
44
44
48
48
56
56
56
78
78
90
90
J
92
92
92
92
92
101
101
101
101
101
114
114
117
124
144
144
144
170
170
200
200
Code No.
CT-787
CT-705
CT-801
CT-244
CT-567
CT-568
CT-597
CT-802
CT-245
CT-569
CT-246
CT-571
CT-596
CT-247
CT-761
CT-807
CT-248
CT-599
CT-808
CT-590
CT-809
PIONEER COPPER TUBE IN-LINE CONNECTORS
Pioneer connectors are designed for jointing low voltage conductors. Made of electrolytic copper tube having the same dimension as CT series lugs, Pioneer connectors are annealed and electrolytically tin plated. They feature an internal taper at both ends to ease the introduction of conductor and a dimple (if required) to ensure correct positioning. These connectors can also be provided with insulation. Tinning on connectors provides betterfinish,avoidsoxidisationandachieves maximum corrosion protection
Material Copper BS: 1977 Finish: Electro Tinned
Size Sq. mm
1.5
2.5
4
6
10
16
25
35
50
70
A
1.6
1.6
2.4
2.4
3.1
3.1
3.8
3.8
3.8
4.5
4.5
4.5
5.4
5.4
6.8
6.8
6.8
8.2
8.2
9.5
9.5
9.5
11.2
11.2
11.2
Dimensions
C
3.2
3.2
4.0
4.0
4.8
4.8
5.5
5.5
5.5
6.2
6.2
6.2
7.1
7.1
8.8
8.8
8.8
10.6
10.6
12.4
12.4
12.4
14.7
14.7
14.7
J
15
22
15
22
15
25
15
22
25
20
22
30
20
35
32
40
47
36
45
40
47
50
40
45
50
Code No.
ILC-1.5/15
ILC-1.5/22
ILC-2.5/15
ILC-2.5/22
ILC - 4 / 1 5
ILC - 4 / 2 5
ILC - 6/15
ILC - 6/22
ILC - 6/25
ILC-10/20
ILC-10/22
ILC-10/30
ILC-16/20
ILC-16/35
ILC-25/32
ILC-25/40
ILC-25/47
ILC-35/36
ILC-35/45
ILC-50/40
ILC-50/47
ILC-50/50
ILC-70/40
ILC-70/45
ILC-70/50
PIONEER COPPER IN-LINE CONNECTORS - INSULATED
Size
Sq. mm
95
120
150
185
240
300
400
500
630
800
1000
A
13.5
13.5
13.5
15.0
15.0
16.5
18.5
21.0
21.0
21.0
23.5
26.8
30.0
35.0
39.0
43.0
Dimensions
C
17.4
17.4
17.4
19.4
19.4
21.2
23.5
26.5
26.5
26.5
30.0
34.8
39.0
45.0
50.6
56.2
J
45
50
60
45
65
55
65
80
85
89
85
90
100
110
150
170
Code No.
ILC-95/45
ILC-95/50
ILC-95/60
ILC-120/45
ILC-120/65
ILC-150/55
ILC-185/65
ILC-240/80
ILC-240/85
ILC-240/89
ILC-300/85
ILC-400/90
ILC-500/100
ILC-630/110
ILC-800/150
ILC-1000/170
INSULATED
Size Sq. mm
1.5
2.5
4.5
A
1.6
2.4
3.5
C
3.2
4.0
5.5
Dimensions
J A1
15
15
15
3.3
4.1
5.6
C1
4.9
5.5
7.2
J1
25
25
27
Code No.
ILCI-63
ILCI-64
ILCI-65
PIONEER EXTENDED PALM BLANKS COPPER CRIMPING TERMINAL ENDS FOR COPPER CONDUCTORS
Pioneer Copper Long Palm Terminals are manufactured from Electrolytic Copper tube. These are used where more secured termination is required as it can easily accommodate two bolts to reduce drift. All terminals are standard with blank palm and stud holes can be punched to order. These terminals are normally used in vibrating applications. The presence of inspection hole facilitates full insertion of conductor. The terminals are tin plated to avoid oxidization and to achieve maximum corrosion protection.
Material Copper BS: 1977 Finish: Electro Tinned
Size Sq. mm
50
70
95
120
150
185
240
300
400
500
625
A
9.5
11.2
13.5
15.0
16.5
18.5
21.0
23.5
28.5
30.0
35.0
c 12.4
14.7
17.4
19.4
21.2
23.5
26.5
30.0
36.5
39.0
45.0
Dimensions
D B
18
21
25
28
30
34
38
43
53
56
65
16
18
20
22
26
32
38
42
44
48
56
G+H
42
50
52
56
64
68
80
88
104
112
132
J
64
75
81
88
101
112
132
145
166
180
210
Code No.
CT-466
CT-467
CT-468
CT-469
CT-470
CT-471
CT-472
CT-473
CT-474
CT-475
CT-476
PIONEER CRIMPING TERMINALS FOR ALUMINIUM
Pioneer CopperTube Crimping Terminals are manufactured from electrolytic copper tube. The dimensions of the tube are designed to obtain the most efficient electrical conductivity and mechanical strength to resist vibration and pull out. These are used for terminating any size of cables, electrical switching equipments, where vibration is critical.
Terminals are annealed to guarantee optimum ductility which is an absolute necessity for connectors which will have to withstand the sever deformation arising when compressed and any bending of the palm during installation. Inapplication subject to vibration, terminals still have to performa reliable connection. Annealing plays a vital role in avoiding cracking or breaks between the barrel and plam. Tin plating on the terminals avoids oxidization and achieves maximum corrossion protection.
Size Sq. mm
2.5
4
6
10
16
25
35
50
70
95
120
150
185
225
240
300
400
500
630
800
1000
n\ VI-K
E
5.2
6.2
6.2
6.2
6.2
6.2
6.2
8.2
6.2
8.2
10.2
8.2
10.2
12.7
10.2
12.7
10.2
12.7
16.2
10.2
12.7
16.2
12.7
16.2
16.2
16.2
20.3
16.2
20.3
20.3
20.3
20.3
-
-
kJI 1 1 1
A
2.0
3.1
3.8
4.4
5.3
7.0
8.0
8.0
9.2
9.2
9.2
11.5
11.5
11.5
12.8
12.8
14.8
14.8
14.8
16.0
16.0
16.0
18.0
18.0
20.0
22.0
22.0
24.0
24.0
28.0
30.0
35.0
39.0
43.0
J\J 1 1 J
Dimensions
C D
3.7
4.8
5.5
6.2
7.1
9.0
10.0
10.0
11.2
11.2
11.2
13.8
13.8
13.8
15.6
15.6
17.8
17.8
17.8
19.6
19.6
19.6
22.0
22.0
24.0
26.0
26.0
28.7
28.7
33.2
36.0
41.5
46.3
53.8
9 11
11
11
11
13
15
15
16
16
16
20
20
20
23 23
26
26 26
28 28 28
32 32
35
38 38 42
42
49
53
61 67
76
B
7
7
9
9 12
12
12
12
16
16
16
18
18
18
20
20
22
22 22
26
26 26
30
30
34
36
36 39
39
44
48
55
65
90
Material Finish
J
20
22
24
24
30 37
37
37
45
45
45
56
56
56
58
58
62
62 62
70
70 70
83
83
95 97
97
103
103
116
120 137
165
210
: Copper BS:1977 : Electro Tinned
Code No.
CT-05
CT-06
CT-07
CT-08
CT-09
CT-10
CT-11
CT-12
CT-13
CT-14
CT-15
CT-16
CT-17
CT-18
CT-19
CT-20
CT-21
CT-22
CT-23
CT-24
CT-25
CT-26
CT-27
CT-28
CT-231
CT-29
CT-30
CT-31
CT-32
CT-33
CT-34
CT-35
CT-62
CT-76
PIONEER COPPER CRIMPING TERMINALS FOR COPPER CONDUCTORS (LONG BARREL)
Pioneer Copper Long Barrel Tube Terminals are made from high purity copper tube and are annealed to avoid cracking or breaks. The increased barrel length ensures enhanced electrical and mechanical performance in heavy duty application. Theabsenceof an inspection hole preventstheentryofwaterormoistureintocrimpedjointsmakingthemsuitableforoutdoorapplications.Theterminalsaretin plated toavoid oxidization and to achieve maximum corrosion protection.
Material Copper BS: 1997 Finish: Electro Tinned
Size Sq. mm
25
35
50
70
95
120
150
185
240
300
400
E
8.2
8.2
8.2
10.5
12.7
12.7
12.7
12.7
16.2
16.2
20.3
A
7.0
8.0
9.2
11.5
12.8
14.8
16.0
18.0
22.0
23.5
26.8
Dimensions
C D
9.0
10.6
12.2
15.0
17.0
19.6
21.2
24.0
28.0
30.0
34.8
13
15
17
20
24
28
30
34
40
43
50
B
16
20
26
28
32
35
38
43
50
55
58
J
41
48
59
66
74
82
86
95
112
120
135
Code No.
CT-82
CT-83
CT-84
CT-85
CT-86
CT-87
CT-88
CT-89
CT-90
CT-91
CT-92
PIONEER DOUBLE HOLE ALUMINIUM CRIMPING TERMINALS FOR CONDUCTORS
Pioneer Double Hole Aluminium Crimping Terminals which are also known as "Non Rotating Terminals" are manufactured out of EC Grade Extrusion tubes drawn to the required sizes having minimum conductivity not less than 60% IACS and are designed as per IS 5082. Two holes ensures non-rotation in the equipments such as transformers.moving equipments where vibration is critical.The holes can be punched as per requirement.
Material: Aluminium IS: 5082
Cable Size Mm2
35
50
70
95
120
150
185
240
300
400
500
E
12
12
12
12
12
16
16
16
16
16
16
A
8
9.7
11
13.1
14.7
16.5
18.1
21
23.2
26
29
c
15
18
18
20
22
25
31
31
38
40
45
Dimensions
D G
22
25
25
28
32
36
45
45
55
58
65
44
44
44
44
44
44
44
44
44
44
44
B
50
50
62
73
73
83
83
86
89
113
125
J
133
133
145
157
160
174
175
180
183
207
221
CAT No.
ATT- 35-12
ATT- 50-12
ATT- 70-12
ATT- 95-12
ATM 20-12
ATM 50-16
ATM 85-16
ATT-240-16
ATT-300-16
ATT-400-16
ATT-500-16
COPPER CRIMPING END SEALING FERRULES Pioneer End Sealing Ferrules are manufactured from electrolytic copper. These ferrules are used when a perfect connection is needed at the end of a cable. Some cables, especially those with small diameters, may conduct badly in electrical connections without an End Sealing Ferrule. By using these ferrules strands, deviation can be avoided and the risk of cable breakage can be reduced. Also these ferrules create a long lasting contact pressure andalarge contact surface. Tinning is provided togivebetterfinish, to avoid oxidisation and to achieve maximum corrosion protection.
Material Copper BS: 1997 Finish: Electro Tinned
Size Sq. mm
0.5
0.75
1.0
1.5
2.5
4.0
6.0
10
16
A
1.0-1.1
1.4-1.5
1.6-1.7
1.6-1.7
1.8-1.9
1.8-1.9
2.3-2.4
2.3-2.4
2.8-2.9
2.8-2.9
3.7-3.8
3.7-3.8
3.7-3.8
4.64.7
4.6-4.7
4.64.7
5.9-6.0
5.9-6.0
5.9-6.0
Dimensions
C
1.4-1.5
1.8-1.9
2.0-2.1
2.0-2.1
2.2-2.3
2.2-2.3
2.7-2.8
2.7-2.8
3.2-3.3
3.2-3.3
4.1-4.2
4.14.2
4.14.2
5.0-5.1
5.0-5.1
5.0-5.1
6.3-6.4
6.3-6.4
6.3-6.4
J
6
6
6
10
7
10
7
12
9
12
10
12
15
12
15
18
12
15
18
Code No.
ES-08
ES-09
ES-10
ES-11
ES-12
ES-13
ES-14
ES-15
ES-16
ES-17
ES-18
ES-19
ES-20
ES-21
ES-22
ES-23
ES-24
ES-25
ES-26
COPPER CRIMPING END SEALING INSULATED FERRULES Pioneer End Sealing Insulated Ferrules are manufactured from electrolytic copper. These ferrules have dimensions according to DIN 46228 and are used when a perfect connection Is needed at the end of a cable. Some cables, especially those with small diameters, may conduct badly in electrical connections without an End Sealing Ferrule. By using these ferrules strands deviation can be avoided and the risk of cable breakage can be reduced. Also these ferrules create a long lasting contact pressure and a large contact surface. Tinning Is provided to give better finish, to avoid oxidisation and to achieve maximum corrosion protection.
The Insulation Sleeve Is manufacture from PP (Polypropylene). We also offer end terminals with Insulation colours according to the most common colour system In the market. The colour of the Insulation sleeves characterises the Cross section area of the conductor.
Material Copper BS: 1997 Finish: Electro Tinned
Size Sq. mm
0.5
0.75
1.0
1.5
2.5
4.0
6.0
10
16
A
1.0-1.1
1.4-1.5
1.6-1.7
1.6-1.7
1.8-1.9
1.8-1.9
2.3-2.4
2.3-2.4
2.8-2.9
2.8-2.9
3.7-3.8
3.7-3.8
3.7-3.8
4.6-4.7
4.64.7
4.6-4.7
5.9-6.0
5.9-6.0
5.9-6.0
Dimensions
C
1.4-1.5
1.8-1.9
2.0-2.1
2.0-2.1
2.2-2.3
2.2-2.3
2.7-2.8
2.7-2.8
3.2-3.3
3.2-3.3
4.1-4.2
4.14.2
4.14.2
5.0-5.1
5.0-5.1
5.0-5.1
6.3-6.4
6.3-6.4
6.3-6.4
J
6
6
6
10
7
10
7
12
9
12
10
12
15
12
15
18
12
15
18
J-1
12
12
12
16
14
16
14
18
16
18
18
20
23
22
25
28
24
27
30
Code No.
ESI - 08
ESI-09
ESI -10
ESI -11
ESI -12
ESI -13
ESI -14
ESI -15
ESI -16
ESI -17
ESI -18
ESI -19
ESI - 20
ESI - 21
ESI - 22
ESI - 23
ESI - 24
ESI-25
ESI - 26
COPPER CRIMPING END SEALING INSULATED FERRULES Pioneer End Sealing Insulated Ferrules are manufactured from electrolytic copper. These ferrules have dimensions according to DIN 46228 and are used when a perfect connection Is needed at the end of a cable. Some cables, especially those with small diameters, may conduct badly in electrical connections without an End Sealing Ferrule. By using these ferrules strands deviation can be avoided and the risk of cable breakage can be reduced. Also these ferrules create a long lasting contact pressure and a large contact surface. Tinning Is provided to give better finish, to avoid oxidisation and to achieve maximum corrosion protection.
The Insulation Sleeve Is manufacture from PP (Polypropylene). We also offer end terminals with Insulation colours according to the most common colour system In the market. The colour of the Insulation sleeves characterises the Cross section area of the conductor.
Material Copper BS: 1997 Finish: Electro Tinned
Size Sq. mm
0.5
0.75
1.0
1.5
2.5
4.0
6.0
10
16
A
1.0-1.1
1.4-1.5
1.6-1.7
1.6-1.7
1.8-1.9
1.8-1.9
2.3-2.4
2.3-2.4
2.8-2.9
2.8-2.9
3.7-3.8
3.7-3.8
3.7-3.8
4.6-4.7
4.64.7
4.6-4.7
5.9-6.0
5.9-6.0
5.9-6.0
Dimensions
C
1.4-1.5
1.8-1.9
2.0-2.1
2.0-2.1
2.2-2.3
2.2-2.3
2.7-2.8
2.7-2.8
3.2-3.3
3.2-3.3
4.1-4.2
4.14.2
4.14.2
5.0-5.1
5.0-5.1
5.0-5.1
6.3-6.4
6.3-6.4
6.3-6.4
J
6
6
6
10
7
10
7
12
9
12
10
12
15
12
15
18
12
15
18
J-1
12
12
12
16
14
16
14
18
16
18
18
20
23
22
25
28
24
27
30
Code No.
ESI - 08
ESI-09
ESI -10
ESI -11
ESI -12
ESI -13
ESI -14
ESI -15
ESI -16
ESI -17
ESI -18
ESI -19
ESI - 20
ESI - 21
ESI - 22
ESI - 23
ESI - 24
ESI-25
ESI - 26
PIONEER LONG BARREL ALUMINIUM CRIMPING TERMINALS FOR ALUMINIUM CONDUCTOR
Pioneer Long Barrel Aluminium Crimping Terminals are manufactured out EC grade extrusion tubes drawn to the required sizes having minimum conductivity not less than 60% IACS and are designed as per IS 5082. These are used for terminating all sizes of cables to terminate electrical switching equipments. The Increased barrel length ensures enhanced electrical and mechanical performance due to more number of crimps. The absence of Inspection hole prevents the entry of water or moisture Into crimped joints making them suitable for outdoor applications.
Cable Size Mm2
2.5
4
6
10
16
25
35
50
70
95
120
150
185
225 240
300
400 500 630 800
1000
E
3.2 3.7 4.2 5.2 5.2 6.4 6.4 8.2 6.4 8.2
10.2
8.2 10.2
12.7
8.2 10.2
8.2 10.2
12.7
8.2 10.2
12.7
10.2
12.7
16.2
10.2
12.7
16.2
10.2
12.7
16.2
10.2
12.7
16.2
12.7
12.7
16.2
16.2
20.3
20.3
20.3
20.3
A
2.0 2.6 2.9 2.9 3.5 3.5 4.4 4.4 5.4 5.4 5.4 7.0 7.0 7.0 8.0 8.0 9.3 9.3 9.3
11.6
11.6
11.6
12.9
12.9
12.9
14.8
14.8
14.8
16.1
16.1
16.1
18.0
18.0
18.0
20.6
22.0
22.0
24.0
24.0
28.0
30.0
35.0
39.0
43.5
Dimensions
C D
5.5 5.5 5.5 5.5 5.5 5.5 7.4 7.4 8.3 8.3 8.3
10.0
10.0
10.0
10.8
10.8
13.0
13.0
13.0
16.0
16.0
16.0
17.1
17.1
17.1
19.6
19.6
19.6
21.2
21.2
21.2
23.7
23.7
23.7
27.0
28.0
28.0
31.0
31.0
36.0
41.0
46.0
51.0
57.0
7.0 7.0 7.0
12.0
8.0 12.0
10.0
15.0
11.0
11.0
18.0
14.0
20.0
20.0
15.0
20.0
18.0
23.0
23.0
22.0
22.0
22.0
25.0
25.0
25.0
28.0
28.0
28.0
31.0
31.0
31.0
34.0
34.0
34.0
39.0
40.0
40.0
45.7
45.7
51.0
58.0
66.0
73.0
81.0
B
10.5
10.5
10.5
10.5
10.5
10.5
13.5
13.5
19.5
19.5
19.5
24.0
24.0
24.0
27.0
27.0
33.0
33.0
33.0
39.0
39.0
39.0
42.0
42.0
42.0
48.0
48.0
48.0
51.0
51.0
51.0
54.0
54.0
54.0
60.0
66.0
66.0
70.5
70.5
84.0
90.0
103.5
115.5
150.0
J
21.5
21.5
21.5
27.5
27.5
27.5
34.5
34.5
43.5
43.5
43.5
52.0
52.0
52.0
56.0
56.0
65.0
65.0
65.0
73.0
73.0
73.0
78.0
78.0
78.0
89.0
89.0
89.0
96.0
96.0
96.0
102.0
102.0
102.0
114.0
124.0
124.0
138.5
138.5
158.0
170.0
188.5
218.5
270.0
CAT NO
AT-551
AT-509
AT-555
AT-517
AT-558
AT-513
AT-514
AT-515
AT-552
AT-516
AT-517
AT-518
AT-519
AT-520
AT-521
AT-522
AT-655
AT-512
AT-524
AT-556
AT-525
AT-526
AT-527
AT-528
AT-529
AT-557
AT-530
AT-531
AT-658
AT-532
AT-533
AT-511
AT-534
AT-535
AT-620
AT-536
AT-537
AT-500
AT-559
AT-560
AT-596
AT-561
AT-618
AT-619
PIONEER OPEN CLOSE SOLDERING TYPE COPPER RING TERMINALS Pioneer Open Close Terminals are made out of EC grade copper. These terminals ensure completeness and ease of conductor entry so that contact is reliable and have more to avoid cracking or breaks and are tin plated to avoid oxidization and to achieve maximum corrosion protection.
Material Copper BS: 1897 Finish: Electro Tinned
Size Sq. mm
1.5
2.5
4
6
10
16
25
35
50
70
95
120
150
185
225
240
300
400
500
625
E
4.2
5.2
5.2
6.5
6.5
8.2
8.2
8.2
10.2
10.2
12.7
12.7
12.7
16.2
16.2
16.2
20.3
20.3
20.3
20.3
A
1.6
2.3
2.8
3.6
4.4
5.4
7.0
8.0
9.5
11.8
13.5
15.5
16.5
18.5
21.0
22.5
25.0
29.5
32.0
36.0
Dimensions
C D
3.2
3.9
4.8
5.6
6.4
7.8
10.2
11.2
13.1
15.8
18.7
21.1
22.9
25.7
28.2
30.5
34.0
39.5
42.8
46.8
7
9
9
12
12
15
15
18
24
28
32
34
38
42
44
48
54
62
62
70
B
5
6
6
7
9
11
14
15
18
23
25
29
30
35
40
42
45
54
58
65
J
15
18
20
24
27
32
36
41
50
58
66
73
79
87
92
100
110
125
137
148
Code No.
OC-71
OC-72
OC-73
OC-74
OC-75
OC-76
OC-77
OC-78
OC-79
OC-80
OC-81
OC-82
OC-83
OC-84
OC-85
OC-86
OC-87
OC-88
OC-89
OC-90
PIONEER COPPER CRIMPING PIN TERMINALS (NON-INSULATED AND INSULATED)
Pioneer Pin Terminals are designed to offer maximum efficiency under heavy-duty applications. Therefore these terminals are Ideal for use In applications which are subject to continuous mechanical vibrations viz. engines, railways, moving components etc. The terminal barrel is brazed and soft annealed, which means that the terminal can be crimped in eitherdirection.
All the terminals are tin plated to avoid oxidisation and to achieve maximum corrossion protection. These terminals can be provided with PVC sleeves for protection against electrical shocks and can also be provided with metal reinforced sleeves to maintainapropergriponconductorinsulation.
Material Copper BS :1897 Finish: Electro Tinned
Size Sq. mm
1.5
2.5
4
6
10
16
25
35
50
70
95
Dimensions
A C D B J
1.6
1.6
2.3
2.3
2.9
3.6
3.6
4.0
4.5
5.8
7.5
9.0
10.5
12.0
13.8
3.2
3.2
3.9
3.9
4.9
5.6
5.6
6.0
6.7
8.2
11.1
12.6
14.1
16.0
18.7
1.9
3.1
1.9
3.1
2.7
5.1
2.7
2.7
4.3
5.5
7.0
8.0
9.0
10.0
11.0
5
5
5
5
6
6
6
6
8
10
11
12
16
18
21
17
17
17
17
20
20
20
20
22
26
31
37
42
45
52
Code No Code No. Code No. TYPE J-1 A-1 J-1
P-9
P-35
P-1
P-2
P-3
P-4
P-5
P-6
P-7
P-8
P-86
P-87
P-88
P-94
P-95
10
10
10
10
14
14
14
14
16
20
PI-17
PI-40
PI-18
PI-19
PI-20
PI-21
PI-22
PI-23
PI-24
PI-25
3.6
3.6
4.4
4.4
6.4
6.4
6.4
6.4
10
10
10
10
15
15
15
15
PD-26
PD-42
PD-27
PD-28
PD-29
PD-30
PD-31
PD-32
PIONEER COPPER CRIMPING PIN TERMINALS (NON-INSULATED AND INSULATED)
Pioneer Pin Terminals are designed to offer maximum efficiency under heavy-duty applications. Therefore these terminals are Ideal for use In applications which are subject to continuous mechanical vibrations viz. engines, railways, moving components etc. The terminal barrel is brazed and soft annealed, which means that the terminal can be crimped in eitherdirection.
All the terminals are tin plated to avoid oxidisation and to achieve maximum corrossion protection. These terminals can be provided with PVC sleeves for protection against electrical shocks and can also be provided with metal reinforced sleeves to maintainapropergriponconductorinsulation.
Material Copper BS :1897 Finish: Electro Tinned
Size Sq. mm
1.5
2.5
4
6
10
16
25
35
50
70
95
Dimensions
A C D B J
1.6
1.6
2.3
2.3
2.9
3.6
3.6
4.0
4.5
5.8
7.5
9.0
10.5
12.0
13.8
3.2
3.2
3.9
3.9
4.9
5.6
5.6
6.0
6.7
8.2
11.1
12.6
14.1
16.0
18.7
1.9
3.1
1.9
3.1
2.7
5.1
2.7
2.7
4.3
5.5
7.0
8.0
9.0
10.0
11.0
5
5
5
5
6
6
6
6
8
10
11
12
16
18
21
17
17
17
17
20
20
20
20
22
26
31
37
42
45
52
Code No Code No. Code No. TYPE J-1 A-1 J-1
P-9
P-35
P-1
P-2
P-3
P-4
P-5
P-6
P-7
P-8
P-86
P-87
P-88
P-94
P-95
10
10
10
10
14
14
14
14
16
20
PI-17
PI-40
PI-18
PI-19
PI-20
PI-21
PI-22
PI-23
PI-24
PI-25
3.6
3.6
4.4
4.4
6.4
6.4
6.4
6.4
10
10
10
10
15
15
15
15
PD-26
PD-42
PD-27
PD-28
PD-29
PD-30
PD-31
PD-32
PIONEER COPPER RING TONGUE FORK TERMINALS Pioneer Ring Tongue Fork Terminals are designed to offer maximum efficiency under heavy-duty applications. Therefore these terminals are ideal for use in applications which are subject to continuous mechanical vibrations viz. engines, railways, moving components etc. The terminal barrel is brazed and softanneaied, which means that the terminal can be crimped ineitherdirection
All the terminals are tin plated to avoid oxidisation and to achieve maximum corrossion protection. These terminals can be provided with PVC sleeves for protection against electrical shocks and can also be provided with metal reinforced sleeves to maintainapropergriponconductorinsulation.
Material Copper BS :1897 Finish: Electro Tinned
Size Sq. mm
1.5
2.5
4-6
10
16
E
3.1
3.6
3.1 3.6 4.1
4.1
5.1
6.1 3.1 3.6 4.1
5.1
6.1 4.1
4.1
5.1
5.1
6.1 4.1
5.1
6.1
8.1
5.1
6.1
8.1
8.1
Dimensions
A
1.6
1.6
1.6
1.6
1.6
1.6
1.6
1.6 2.3
2.3
2.3 2.3
2.3
3.5 3.5 3.5 3.5 3.5
4.3
4.3
4.3
4.3
5.6
5.6 5.6 5.6
c
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.9
3.9
3.9
3.9
3.9
5.5
5.5
5.5
5.5
5.5
6.3
6.3
6.3
6.3
8.0
8.0
8.0
8.0
D
6.0
6.0
6.8
6.8
7.0
8.0
10.0
10.0
6.5
6.5
8.0
10.0
10.0
8.0
10.0
10.0
10.0
12.0
10.0
10.0
12.0
16.0
10.0
12.0
16.0
18.0
B
5
5
5
5
5
5
5
5
5
5
5
5
5
6
6
6
6
6
8
8
8
8
10
10
10
10
J
14 14 13
13
14
16
18
18 12.7
12.7
16
18
18
17
19
19
22
22
22
22
23
27
24
26
30
33
Code No.
RF-235
RF-240
RF-241
RF-244
RF-237
RF-236
RF-238
RF-861 RF-862
RF-863
RF-239 RF-242
RF-864
RF-243
RF-245
RF-246
RF-247
RF-248
RF-865
RF-866
RF-867
RF-868
RF-869
RF-870 RF-871
RF-872
Dim. J-1
10
10
10
10
10
10
10
10
10
10
10
10
10
14
14
14
14
14
16
16
16
16
----
Code No.
RFI-873
RFI-874
RFI-875
RFI-876
RFI-877
RFI-878
RFI-879
RFI-880
RFI-881 RFI-882
RFI-883 RFI-884
RFI-885
RFI-886
RFI-887
RFI-888
RFI-889
RFI-890
RFI-891
RFI-892
RFI-893
RFI-894
— — — —
Dimensions
A-1
3.6 3.6 3.6 3.6 3.6 3.6
3.6
3.6 4.4 4.4 4.4
4.4
4.4
6.4 6.4 6.4 6.4 6.4
6.8
6.8
6.8
6.8
----
J-1
10 10
10
10 10 10
10
10 10 10 10 10 10 15 15 15 15 15 17 17 17 17
----
Code No.
RFD-899
RFD-900
RFD-901
RFD-902
RFD-903
RFD-904
RFD-905
RFD-906 RFD-907
RFD-908
RFD-909
RFD-910 RFD-911
RFD-912
RFD-913
RFD-914
RFD-915
RFD-916
RFD-917
RFD-918
RFD-919
RFD-920
PIONEER COPPER CRIMPING RING TERMINALS (NON-INSULATED AND INSULATED)
Pioneer Ring Terminals are designed to offer maximum efficiency under heavy-duty applications. Therefore these terminals are ideal for use in applications which are subject to continuous mechanical vibrations viz. engines, railways, moving components etc. The terminal barrel is brazed and soft annealed, which means that the terminal can be crimped in either direction.
All the terminals are tin plated to avoid oxidization and to achieve maximum corrosion protection.These terminals can be provided with PVC sleeves for protection against electrical shocks and can also be provided with metal reinforced sleeves to maintainapropergriponconductorinsulation.
Material Copper BS: 1897 Finish: Electro Tinned
Size Sq. mm
1.5
Dimensions
E A C D B J
2.2
2.6
3.2
3.7
4.2
3.2
3.7
4.2
3.2
4.2
5.2
4.2
4.2
5.2
6.4
6.4
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
3.2
6.0
6.0
6.0
6.0
6.0
6.8
6.8
6.8
8.0
8.0
8.0
7.0
10.0
10.0
10.0
12.0
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
14.0
14.0
14.0
14.0
14.0
13.0
13.0
13.0
16.0
16.0
16.0
14.5
18.0
18.0
18.0
18.0
J-1 A-1 J-1
R-103
R-000
R-001
R-002
R-003
R-153
R-048
R-049
R-104
R-004
R-005
R-154
R-105
R-006
R-007
R-106
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
Rl - 052
Rl - 053
RI-054
Rl - 055
Rl - 056
Rl - 057
Rl - 058
Rl - 059
Rl- 060
RI-061
Rl - 062
Rl - 063
Rl - 064
Rl - 065
Rl - 066
Rl - 067
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
3.6
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
RD-435
RD-436
RD-437
RD-438
RD-439
RD-440
RD-441
RD-442
RD-443
RD-444
RD-445
RD-446
RD-447
RD-448
RD-449
RD-450
Size Sq. mm
2.5
4-6
10
Dimensions
E A C D B J
3.2 3.7 3.7 4.2 5.2 5.2 6.4 5.2 6.4 8.2 6.4 8.2
10.2
10.2 12.7 4.2 5.2 4.2 5.2 5.2 5.2 6.4 8.2 5.2 6.4 6.4 8.2 9.7 8.2
10.2 8.2
10.2 12.7
4.2 8.2
2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 4.3 4.3
3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 3.9 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 6.3 6.3
6.5 6.5 8.0 8.0 8.0
10.0 10.0 12.0
12.0 12.0
16.0 16.0
16.0 18.0 18.0
8.0 8.0
10.0 10.0 8.0
12.0 12.0
12.0 12.0 12.0
14.0 14.0
14.0 16.0 16.0
18.0 18.0
18.0 10.0 18.0
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 8 8
12.7
12.7 16.0
16.0 16.0
18.0 18.0 22.0
22.0 22.0
25.0 25.0
25.0 29.0 29.0
17.0 17.0
19.0 19.0 22.0
20.0 20.0
20.0 22.0 22.0
25.5 25.5
25.5 30.0 30.0
30.0 30.0
30.0 22.0 22.0
Code No. Code No. Code No.
J-1 A-1 J-1
R-107
R-008 R-108
R-009 R-010
R-109 R-011 R-110 R-012
R-013 R-111
R-014
R-015 R-151 R-047
R-155 R-050 R-112
R-016 R-157
R-113 R-017
R-018 R-114 R-019
R-115 R-020 R-021
R-116 R-022 R-117
R-023 R-024
R-118 R-025
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 16 16
Rl- 068 Rl- 069 Rl - 070 Rl - 071
Rl - 072
Rl - 073 Rl - 074 Rl - 075
Rl - 076 Rl - 077
Rl - 078 Rl - 079
Rl - 080 Rl - 081 Rl - 082
Rl - 083 Rl - 084
Rl - 085 Rl - 086 Rl - 087
Rl - 088 Rl - 089
Rl - 090 Rl - 091 Rl - 092
Rl - 093 Rl - 094
Rl - 095 Rl - 096 Rl - 097
Rl - 098 Rl - 099
Rl -100 Rl - 389 Rl - 395
4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.8 6.8
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 17 17
RD-451 RD-452 RD-453 RD-454
RD-455
RD-456 RD-457 RD-458
RD-459 RD-460
RD-461 RD-462
RD-463 RD-464 RD-465
RD-466 RD-467
RD-468 RD-469 RD-470 RD-471
RD-472
RD-473 RD-474 RD-475
RD-476 RD-477
RD-478 RD-479 RD-480
RD-481 RD-482
RD-483 RD-484 RD-485
PIONEER COPPER CRIMPING RING TERMINALS (NON-INSULATED)
Size Sq. mm
10
16
25
Dimensions
E A C D B J
5.2
6.4
8.2
8.2
10.2
10.2
12.7
5.2
5.2
6.4
6.4
8.2
9.7
8.2
10.2
10.2
12.7
6.4
8.2
6.4
8.2
10.2
6.4
8.2
10.2
10.2
12.7
4.3
4.3
4.3
4.3
4.3
4.3
4.3
5.6
5.6
5.6
5.6
5.6
5.6
5.6
5.6
5.6
5.6
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
7.5
6.3
6.3
6.3
6.3
6.3
6.3
6.3
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
10
12
16
18
18
22
22
10
12
12
16
16
16
18
18
22
22
12
12
16
16
16
16
16
18
22
22
8
8
8
8
8
8
8
10
10
10
10
10
10
10
10
10
10
11
11
11
11
11
11
11
11
11
11
20
23
27
30
30
34
34
24
26
26
30
30
30
33
33
35
35
31
31
30
30
30
33
33
34
42
42
Code No.
R-026
R-120
Ft-121
R-122
R-027
R-123
R-028
R-124
R-125
R-029
R-126
R-030
R-031
R-127
R-032
R-128
R-033
R-156
R-051
R-129
R-034
R-035
R-130
R-036
R-131
R-132
R-037
Size Sq. mm
35
50
70
95
120
150
E
6.4
8.2
8.2
10.2
10.2
12.7
8.2
10.2
10.2
10.2
12.7
16.2
10.2
12.7
12.7
16.2
10.2
10.2
12.7
16.2
12.7
16.2
20.3
12.7
16.2
20.3
A
9.0
9.0
9.0
9.0
9.0
9.0
10.5
10.5
10.5
10.5
10.5
10.5
12.0
12.0
12.0
12.0
13.5
13.5
13.5
13.5
15.0
15.0
15.0
16.5
16.5
16.5
Dimensions
C D
12.6
12.6
12.6
12.6
12.6
12.6
14.1
14.1
14.1
14.1
14.1
14.1
16.0
16.0
16.0
16.0
18.1
18.1
18.1
18.1
20.2
20.2
20.2
23.7
23.7
23.7
16
16
18
18
22
22
18
18
22
24
24
32
22
22
24
28
22
24
24
28
26
32
40
34
34
40
B
12
12
12
12
12
12
16
16
16
16
16
16
18
18
18
18
20
20
20
20
22
22
22
24
24
24
J
31
31
36
36
42
42
43
43
43
48
48
54
47
47
48
54
46
50
50
58
52
64
72
66
66
74
Code No.
R-133
R-038
R-134
R-039
R-135
R-040
R-136
R-041
R-137
R-138
R-042
R-139
R-140
R-043
R-141
R-142
R-143
R-144
R-044
R-145
R-146
R-147
R-148
R-149
R-045
R-046
SNAP ON TERMINALS
Pioneer Snap On Terminals are made out of Phosphorus bronze These are used In electrical and electronic Installations like PCB mounted devices, electronic power relays etc. These can also be provided with Insulation.
SNAP ON TERMINALS
Pioneer Snap On Terminals are made out of Phosphorus bronze These are used in electrical and electronic installations like PCB mounted devices, electronic power relays etc. These can also be provided with insulation.
PROCESS OF MANUFACTURING CABLE LUGS
SCOPE OF LUGS:
The Cable Lugs are used for termination of cables to the equipments and connectors used to extend the cables. The cable sizes vary as per the electric current requirements. Generally, cable sockets/terminals used shall be of
E. C. Grade copper. The cable sockets shall be duly tin plated for outer finish and to with stand the corrosion while storage and use.
PROCESS
A) EXTRUSIONS:
The cable Lugs & Connectors of various sizes are manufactured out of copper EC Grade wire bars. These wire bars are cut into 3 to 4 parts for melting. These are refined and cast into round ingots as per required sizes. These
ingots undergo a process of cutting, which finally turns into the extrusion billets. These billets are drilled as per required I.D. of the internal diameter of tubes. These are further heated in gas fired furnaces to appropriate extrusion
temperature. The heated billets are then extruded by hydropneumatic press into the mothertubes of required sizes. Three types of mothertubes are used for copper cable sockets.
I.D.
O.D.
50
64
38
50
37.5
40
B) TUBE DRAW: The copper mothertubes are finally made to required size of coppertubes which vary as per size of cable. The chart shows the various sizes of coppertubes used. The dimension 'C is 0. D. and 'A' is I. D. of Tube required for the
particular cable terminal. The process is called tube drawing process. The mothertubes are drawn in draw bench with required T.C. dies of O.D, and plug for required I. D.
During the process the copper undergoes annealing process and each time the tube is made to smaller size by swaging machine so that the pipe to be pulled at the beginning of pipe. This swaged pipes are pulled in draw bench
every time it passes through small T.C. dies to reduce the diameters and every time these are annealed in heating furnace which gives burning and annealing loss.
C) CABLE LUGS MANUFACTURING: The drawn tubes are finally cut into pieces in cutting machine to the required length of cable lugs and are chamfered. The cut tubes are finally annealed in annealing furnace and forged to make the palm of socket and in cutting
process the front arc and hole is made. The lugs are then marked with required code number and size of cable.After this the lugs are ready for plating.
D) TINNING PROCESS The cable lugs are finally acid tinned in the plating plant. The tinning process is required for surface finish as well as to avoid corrosion whilst storage and use.
The cable sockets are finally checked and packed in boxes with sizes marked on the box. These boxes are finally packed in master carton for the final dispatch in export worthy packing.
All the process checked at each stage are as per the quality assurance plan.
SOLDERING TYPE COPPER TERMINALS (LIGHT DUTY)
Pioneer Soldering Type Copper Terminals are made out of EC grade copper and used where high value of current flow is desired and due to soldering loose terminations are avoided, thereby preventing heating at termination ends. Terminals are tin plated to avoid oxidization and to achieve maximum corrossion protection.
Material Copper BS: 1977 Finish: Electro Tinned
AMPS
15
30
60
100
150
200
300
400
500
600
800
1000
1000
E
3.2
5.1
6.4
9.5
9.5
12.7
12.7
15.9
19.0
19.0
23.8
23.8
A
3.9
5.2
8.1
10.9
13.9
16.6
19.0
22.2
25.4
27.8
31.7
38.1
50.0
Dimensions
C D
4.8
6.3
9.5
12.7
15.9
19.0
22.2
25.4
28.6
31.8
38.1
44.5
57.3
7
9
14
19
24
28
33
38
43
47
56
66
85
B
7
9
14
19
23
27
28
32
38
44
47
56
62
J
19
23
36
49
57
66
80
89
105
115
121
152
164
Code No.
CTS - 01
CTS - 02
CTS - 03
CTS-04
CTS - 05
CTS - 06
CTS - 07
CTS - 08
CTS - 09
CTS-10
CTS-11
CTS-12
CTS - 95
SOLDERING TYPE COPPER TERMINALS (HEAVY DUTY)
Pioneer Soldering Type Heavy Duty Copper Terminals are made out of EC grade copper and used where high value of current flow is desired and due to soldering loose terminations are avoided, thereby preventing heating at termination ends. Terminals are tin plated to avoid oxidization and to achieve maximum corrossion protection.
Material Copper BS: 1977 Finish: Electro Tinned
AMPS
15
30
60
100
150
200
300
400
500
300
500
630
E
5.1
7.1
10.3
11.9
13.5
13.5
16.7
16.7
19.8
18.0
22.0
26.0
A
4.8
6.4
9.5
11.9
14.3
16.7
20.6
23.8
26.2
26.2
31.7
36.5
Dimensions
C D
6.2
8.0
11.3
13.9
17.1
19.9
24.2
27.8
31.4
34.2
40.9
46.1
9
12
17
21
25
29
36
41
46
49
59
67
B
10
13
14
19
22
29
32
38
44
44
48
56
J
24
33
44
55
62
78
86
100
111
111
121
139
Code No.
BSS-6
BSS-7
BSS-8
BSS-9
BSS-10
BSS-11
BSS-12
BSS-13
BSS -14
BSS - 28
BSS - 29
BSS-30
SOLDERING TYPE COPPER WEAK BACK FERRULES
Pioneer Soldering Type Weak Back Ferrules are manufactured out of copper and are used to solder straight through joints. Tinning is provided to give better finish, to avoid oxidisation and to achieve maximum corrosion protection.
Material Copper BS: 1997 Finish: Electro Tinned
Size Sq. mm
6
10
16
25
35
50
70
95
120
150
185
225
240
300
400
500
625
A
3.0
4.4
5.5
7.0
8.0
9.5
12.0
13.5
15.5
17.0
18.5
20.5
22.0
24.0
28.5
30.5
34.5
c 4.6
6.0
7.5
9.0
10.4
11.9
14.8
16.3
18.7
20.6
22.9
24.9
26.4
29.6
34.7
37.5
42.5
Dimensions
G L
2
2
2
2
2
2
3
3
4
4
4
5
5
5
7
7
8
20
25
25
30
35
40
45
50
55
60
65
75
80
85
95
105
115
T
0.8
0.8
1.0
1.0
1.2
1.2
1.4
1.4
1.6
1.8
2.2
2.2
2.2
2.8
3.1
3.5
4.0
P
3
4
5
7
8
9
12
13
15
16
18
20
21
23
27
30
33
Code No.
WB-79
WB-80
WB-81
WB-82
WB-83
WB-84
WB-85
WB-86
WB-87
WB-88
WB-89
WB-90
WB-91
WB-92
WB-93
WB-94
WB-95