Cable Lugs used on Flexible Cable

[surferdude]

Can normal cable lugs be used on flexible cables?

Crimp type lug: Burndy HYLUG YA35L
- listed for 550 kcmil, code conductor

Crimp type lug: Burndy HYLUG YA34L
- listed for 500 kcmil, code conductor

Cable type: Amercable Flexible Power Cable 4core x 535 kcmil
- Copper conductors flexible stranded to IEEE 1580 Table 11.

 

[mcgyvr]

You will have to look at the barrel id and conductor od to verify but typically for flexible cable you need to go up 1 size on the lugs.
In my industry we have whats called telcoflex cable and for a 350kcmil conductor you use a 500kcmil compression lug.

 

[sibeen]

I'd concur with mcgyvr. I work in the IEC world where the cable sizes are in mm^2.

If the flexible cable was 35 mm^2 then I'd use a 50 mm lug.

 

[alehman]

Lugs intended for code conductor are not necessarily approved for other types. If approval by an electrical testing laboratory is important (e.g. UL), make sure it is listed for the cable. Just going one side larger doesn't always qualify.

Alan
----
"It’s always fun to do the impossible." - Walt Disney

 

[LionelHutz]

If you look in the catalog there will be lugs rated for dual use with a second wire size given for flex cable.

 

[electricpete]

You face two problems if you don't go to larger lug size for flex cable.

1 - The O.D. of the finely stranded cable is SLIGHTLY larger.

2 - The finely stranded wire has more strands (of course) and it is more of a challenge to get them all into the lug barrel. Bell mouth lug makes it easier.


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[electricpete]

I did not realize that many lugs have dual use rating mentioned above. Are there any handy links to examples of that?

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[mcgyvr]

We get all our lugs from Panduit.
On their LCDX Flex Conductor lugs for example they call out can be used with code conductors and flex conductors class G, H, I, K, M and Locomotive. They also list in the tables in their catalog a part number for the lug, then 3 columns next to it which tell what size Class/Locomotive/Code conductors it will fit/approved on. Then for my sanity, I always check the drawing where it shows the ID of the lug and then check the conductor diameter for the appropriate wire I've spec'd. Make sure you get the appropriate/approved crimping die set also..

Nothing worse than stripping a 750kcmil wire and finding it doesn't fit into the 35 dollar non-returnable compression lug you just bought. Wire birdcaging is not acceptable, neither is cutting strands till it fits... (seen it done many times though).

From what I've seen if you spec the correct wire and lug the bellmouth style is not needed at all. It also typically cost more too.

 

[catserveng]

Here is a link to a T&B catalog page, shows flex cable sizing for lugs in seperate. Also some catalogs will show flex sizing in (). Have seen the same for Burndy and others.

https://www.alliedelec.com/Catalog/catalogpages/200809/348.pdf

 

[surferdude]

Thanks everyone for all the valuable contributions.

I've decided to get Burndy lugs specifically listed for flexible conductors. Catalog page is attached.

website page:

http://portal.fciconnect.com/portal/page/portal/FcicntPublic/Product_Type?appname=catLanding

 

[electricpete]

Thanks mcgyvr and catserveng

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[surferdude]

Just to share something which I thought to be interesting..

IEEE 1580 Table 11 lists conductor diameters for "Flexible Cables". This matches with the Amercable flexible cable that I have.

IEEE 1580 Table 10 lists conductor diameter for "Standard Class B cables". I assume this is the what is applicable for "normal non flexible cable".

Comparing the information in an Excel table (see attached) the diffference in conductor diamater:
- 600kcmil (Class B cable): diameter 0.893"
- 535kcmil (Flex cable): diameter 0.941"
--> Difference in diameter is just 0.048" or 1.2192mm which is really quite small!!

 

[electricpete]

Yes, 5% difference - not a heckuva lot. This table seems to show 6, 8, 10AWG finely stranded is smaller than standard... what's up with that?

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[REDDOG]

Verify that you are using a Code Recognized type of cable not” Locomotive” only rating.