Heavy Duty Battery Connectors
403030.02CK
3/11/02
3:17 PM
Page 74
COMPRESSION
Heavy Duty Battery Connectors Color-Keyed Starter Lugs – Tin Plated Cat. No.
BAL1038
T& B
2/0 BATT
ORANGE
2/0 BATT
BAL414 BAL4516 BAL438 BAL2516 BAL238 BAL212 BAL1516 BAL138 BAL112 BAL10516 BAL1038 BAL1012 BAL20516 BAL2038 BAL2012 BAL30516 BAL3038 BAL3012 BAL40516 BAL4038 BAL4012
Bulk Cat. No.
SAE Cable Size and Color
Stud Size
A ±04
B ±02
C ±02
D ±02
273-31852-1 273-31852-2 273-31852-3
4 Gauge 4 Gauge 4 Gauge 2 Gauge 2 Gauge 2 Gauge 1 Gauge 1 Gauge 1 Gauge 1/0 Gauge 1/0 Gauge 1/0 Gauge 2/0 Gauge 2/0 Gauge 2/0 Gauge 3/0 Gauge 3/0 Gauge 3/0 Gauge 4/0 Gauge 4/0 Gauge 4/0 Gauge
b j c j c d j c d j c d j c d j c d j c d
140 145 145 159 178 177 183 185 220 192 193 197 206 211 211 216 203 235 240 228 260
52 61 61 69 67 76 76 75 75 83 83 88 93 93 93 103 103 103 113 112 112
40 36 36 40 55 54 49 55 75 50 55 53 50 55 55 55 55 75 59 55 75
115 114 114 125 140 140 150 150 170 150 155 153 160 165 165 165 165 185 184 190 210
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Pkg. Bulk Color Qty. Pkg. Qty. Key
273-31852-4 273-31852-5 273-31852-6 273-31852-7 273-31852-8 273-31852-9 273-31852-10 273-31852-11 273-31852-12 273-31852-13 273-31852-14 273-31852-15
Pkg. Bulk Color Qty. Pkg. Qty. Key 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100
Grey Grey Grey Green Green Green Pink Pink Pink Black Black Black Orange Orange Orange Purple Purple Purple Yellow Yellow Yellow
Material: High conductivity copper. Finish: Electro-tin plated. Installing Tools: TBM5-SV or TBM5V.
Stackable Battery Connector – Lead Plated Cat. No.
BAC1038
BAC438 BAC238 BAC138 BAC1038 BAC2038 BAC3038 BAC4038
Bulk Cat. No.
SAE Cable A M Size and Color ±.040 ±.020
273-31853-1 273-31853-2 273-31853-3 273-31853-4 273-31853-5 273-31853-6 273-31853-7
4 Gauge 2 Gauge 1 Gauge 1/0 Gauge 2/0 Gauge 3/0 Gauge 4/0 Gauge
1.455 1.775 1.875 1.925 2.110 2.025 2.275
1.143 1.400 1.500 1.550 1.645 1.650 1.900
W ±020
C ±.020
E ±.010
Stud Size
.615 .675 .750 .825 .930 1.025 1.125
.750 .850 .950 1.000 1.100 1.100 1.350
.365 .467 .521 .571 .632 .701 .766
c c c c c c c
10 10 10 10 10 10 10
100 100 100 100 100 100 100
Grey Green Pink Black Orange Purple Yellow
74
2/0 BATT 2/0 BATT
ORANGE
ORANGE
Material: High conductivity copper. Finish: Electro-tin plated. Installing Tools: TBM5-SV or TBM5V.
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
403030.01CK
3/11/02
3:28 PM
Page 6
Color-Keyed® Connectors COMPRESSION
® ®
Color-Keyed ® Special Lugs for Special Problems – Angled, Shaped and Trimmed the Way You Often Need Them Thomas & Betts can solve your difficult wire bending and terminating problems in confined power distribution panels, switchgear and motor control enclosures. We have the design and production capability to deliver exactly the type lug you need, shaped the way you need. • Straight, 45° and 90° angle • Stacking or non-stacking • Narrow tongue or standard • Tin, silver, lead, nickel Thomas & Betts offers an extensive line of copper Color-Keyed® lugs for #8 AWG through 1000 kcmil flex and code cables. The lug tongues are modified in several different configurations to meet your exact needs: 45° and 90° bend angles, narrow tongues to fit into circuit breakers, offset tongues to stack two cables, and special stud hole drilling. These special configurations let you: (1) run cable directly to the bus bar with no bending, (2) terminate into very narrow spaces, and (3) utilize minimal bus bar space. The specially designed lugs help you “clean up” your cabling in crowded enclosures. The photographs show some examples of how and where the lugs can be used.
Customized Color-Keyed ® Connectors for Copper Cables • Standard and special tongue angles, stacking and non-stacking, bolt holes sizes and centers, protective platings. • Specially modified one and two hole copper Color-Keyed® compression lugs, Series 54100, 54200, 54850BE and 54930BE for flex and code copper stranded cables. Material high conductivity wrought copper. • Minimum order quantity: Standard package quantity by cable size. Consult factory for price and delivery. All customized lugs are made to order. A.R.O. Non-cancellable.
6
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
403030.01CK
3/11/02
3:28 PM
Page 8
COMPRESSION
Color-Keyed® Connectors Tongue Specifications – See Chart “A” For Dimensions Stud Sizes □ #8 □d □ #10 □e □b □f □j □g □c □ 1
Double Hole
Single Hole
Blank
Chart A Nominal Bolt Hole Size .015 #8 #10 b j c d e f *g *1
Hole Wrench Offset Clearance .030 Min.
.173 .204 .281 .344 .406 .531 .656 .812 .937 1.062
.200 .218 .250 .375 .375 .500 .812 .750 .875 .937
.240 .250 .312 .406 .440 .562 .875 .770 .890 1.000
#8 Code #8 Weld .406 .406 .469 .562 .578 – – – – –
#6 Code #6 Weld #4 Code .437 .437 .500 .562 .578 – – – – –
.562 .562 .562 .562 .594 – – – – –
#2 Code #4 Weld .593 .593 .593 .675 .675 .750 – – – –
Tongue Width Cable Size #1 Code 1/0 Code #2 Weld #1 Weld .672 .672 .672 .672 .672 .750 – – – –
.750 .750 .750 .750 .750 .750 – – – –
2/0 Code 1/0 Weld
3/0 Code 2/0 Weld
4/0 Code 3/0 Weld
250 Code
.825 .825 .825 .825 .825 .825 – – – –
.937 .937 .937 .937 .937 .937 .937 – – –
1.030 1.030 1.030 1.030 1.030 1.030 1.030 – – –
1.125 1.125 1.125 1.125 1.125 1.125 1.125 – – –
* These bolt holes available in one hole lug only.
Chart B Cable Size #8 #6 #4 #2 #1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000
Tongue Thickness .080 .081 .099 .108 .106 .125 .125 .125 .137 .137 .153 .177 .173 .218 .244 .228 .270 .266 .313 .297
Straight Lug Barrel Length Plus Transition Short Long
Barrel O.D. I.D.
.635 .675 .685 .815 .825 .975 .965 1.085 1.255 1.375 1.900 2.090 2.460 2.670 2.900 2.784 3.050 3.213 3.450 3.356
.260 .296 .365 .410 .467 .571 .571 .632 .701 .766 .850 .926 .960 1.100 1.200 1.255 1.330 1.375 1.500 1.550
.935 .975 .985 1.115 1.275 1.325 1.315 1.435 1.705 1.925 2.675 2.896 2.980 3.610 3.490 3.925 4.550 4.500
.180 .215 .266 .302 .361 .396 .446 .507 .564 .629 .660 .720 .757 .852 .926 .997 1.030 1.079 1.145 1.203
Straight
Dim “X” Stacked Lugs 45°
90°
Dim “Y” Short Long
Dim “H” Short Long
.158 .134 .175 .216 .212 .250 .250 .250 .274 .274 .459 .531 .519 .654 .732 .684 .810 .800 .940 .890
.478 .544 .622 .649 .731 .789 .859 .946 1.031 1.123 1.226 1.333 1.370 1.514 1.630 1.662 1.745 1.728 1.900 2.070
.394 .432 .502 .535 .592 .646 .696 .757 .826 .891 .975 1.103 1.085 1.225 1.325 1.375 1.455 1.625 1.650 1.675
.595 .587 .637 .711 .710 .794 .829 .900 1.015 1.085 1.180 1.267 1.551 1.629 1.762 1.780 1.827 1.952 2.065 2.031
.779 .767 .838 .958 .956 1.075 1.125 1.225 1.387 1.487 1.924 2.096 2.484 2.669 2.897 3.011 3.050 3.213 1.387 1.487
.808 .799 .849 .923 1.028 1.042 1.077 1.148 1.333 1.474 1.726 1.830 1.913 2.266 2.147 2.434 2.787 2.787
1.079 1.067 1.138 1.258 1.406 1.425 1.475 1.575 1.837 2.037 2.679 2.896 2.984 3.619 3.497 3.925 4.554 4.506
Note: Stacking lugs are available for one bolt only. Consult Factory: Straight: 700 kcmil & up 45°: 400 kcmil & up 90°: 500 kcmil & up
8
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
403030.01CK
3/11/02
3:28 PM
Page 9
Color-Keyed® Connectors COMPRESSION
Formula 1 = (.125 + 2 (OD) + .037 – Tongue Thickness)
Chart C Tongue Width .030 Code Cable Size Bolt Hole Size
300 kcmil 4/0 Weld
350 kcmil
400 kcmil
500 kcmil 400 Weld
600 kcmil 500 Weld
1325/24
700 kcmil
750 kcmil
800 kcmil
900 kcmil
1000 kcmil
#8 #10 b j c d e f *g *1
– – 1.250 1.250 1.250 1.250 1.250 1.250 – –
– – 1.355 1.355 1.355 1.355 1.355 1.355 – –
– – 1.410 1.410 1.410 1.410 1.410 1.410 – –
– – 1.605 1.605 1.605 1.605 1.605 1.605 1.605 –
– – 1.745 1.745 1.745 1.745 1.745 1.745 1.745 1.745
– – 1.805 1.805 1.805 1.805 1.805 1.805 1.805 1.805
– – 1.840 1.840 1.840 1.840 1.840 1.840 1.840 1.840
– – 1.935 1.935 1.935 1.935 1.935 1.935 1.935 1.935
– – 2.010 2.010 2.010 2.010 2.010 2.010 2.010 2.010
– – 2.180 2.180 2.180 2.180 2.180 2.180 2.180 2.180
– – 2.265 2.265 2.265 2.265 2.265 2.265 2.265 2.265
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
9
3/11/02
3:17 PM
Page 74
COMPRESSION
Heavy Duty Battery Connectors Color-Keyed Starter Lugs – Tin Plated Cat. No.
BAL1038
T& B
2/0 BATT
ORANGE
2/0 BATT
BAL414 BAL4516 BAL438 BAL2516 BAL238 BAL212 BAL1516 BAL138 BAL112 BAL10516 BAL1038 BAL1012 BAL20516 BAL2038 BAL2012 BAL30516 BAL3038 BAL3012 BAL40516 BAL4038 BAL4012
Bulk Cat. No.
SAE Cable Size and Color
Stud Size
A ±04
B ±02
C ±02
D ±02
273-31852-1 273-31852-2 273-31852-3
4 Gauge 4 Gauge 4 Gauge 2 Gauge 2 Gauge 2 Gauge 1 Gauge 1 Gauge 1 Gauge 1/0 Gauge 1/0 Gauge 1/0 Gauge 2/0 Gauge 2/0 Gauge 2/0 Gauge 3/0 Gauge 3/0 Gauge 3/0 Gauge 4/0 Gauge 4/0 Gauge 4/0 Gauge
b j c j c d j c d j c d j c d j c d j c d
140 145 145 159 178 177 183 185 220 192 193 197 206 211 211 216 203 235 240 228 260
52 61 61 69 67 76 76 75 75 83 83 88 93 93 93 103 103 103 113 112 112
40 36 36 40 55 54 49 55 75 50 55 53 50 55 55 55 55 75 59 55 75
115 114 114 125 140 140 150 150 170 150 155 153 160 165 165 165 165 185 184 190 210
10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
Pkg. Bulk Color Qty. Pkg. Qty. Key
273-31852-4 273-31852-5 273-31852-6 273-31852-7 273-31852-8 273-31852-9 273-31852-10 273-31852-11 273-31852-12 273-31852-13 273-31852-14 273-31852-15
Pkg. Bulk Color Qty. Pkg. Qty. Key 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100
Grey Grey Grey Green Green Green Pink Pink Pink Black Black Black Orange Orange Orange Purple Purple Purple Yellow Yellow Yellow
Material: High conductivity copper. Finish: Electro-tin plated. Installing Tools: TBM5-SV or TBM5V.
Stackable Battery Connector – Lead Plated Cat. No.
BAC1038
BAC438 BAC238 BAC138 BAC1038 BAC2038 BAC3038 BAC4038
Bulk Cat. No.
SAE Cable A M Size and Color ±.040 ±.020
273-31853-1 273-31853-2 273-31853-3 273-31853-4 273-31853-5 273-31853-6 273-31853-7
4 Gauge 2 Gauge 1 Gauge 1/0 Gauge 2/0 Gauge 3/0 Gauge 4/0 Gauge
1.455 1.775 1.875 1.925 2.110 2.025 2.275
1.143 1.400 1.500 1.550 1.645 1.650 1.900
W ±020
C ±.020
E ±.010
Stud Size
.615 .675 .750 .825 .930 1.025 1.125
.750 .850 .950 1.000 1.100 1.100 1.350
.365 .467 .521 .571 .632 .701 .766
c c c c c c c
10 10 10 10 10 10 10
100 100 100 100 100 100 100
Grey Green Pink Black Orange Purple Yellow
74
2/0 BATT 2/0 BATT
ORANGE
ORANGE
Material: High conductivity copper. Finish: Electro-tin plated. Installing Tools: TBM5-SV or TBM5V.
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
403030.01CK
3/11/02
3:28 PM
Page 6
Color-Keyed® Connectors COMPRESSION
® ®
Color-Keyed ® Special Lugs for Special Problems – Angled, Shaped and Trimmed the Way You Often Need Them Thomas & Betts can solve your difficult wire bending and terminating problems in confined power distribution panels, switchgear and motor control enclosures. We have the design and production capability to deliver exactly the type lug you need, shaped the way you need. • Straight, 45° and 90° angle • Stacking or non-stacking • Narrow tongue or standard • Tin, silver, lead, nickel Thomas & Betts offers an extensive line of copper Color-Keyed® lugs for #8 AWG through 1000 kcmil flex and code cables. The lug tongues are modified in several different configurations to meet your exact needs: 45° and 90° bend angles, narrow tongues to fit into circuit breakers, offset tongues to stack two cables, and special stud hole drilling. These special configurations let you: (1) run cable directly to the bus bar with no bending, (2) terminate into very narrow spaces, and (3) utilize minimal bus bar space. The specially designed lugs help you “clean up” your cabling in crowded enclosures. The photographs show some examples of how and where the lugs can be used.
Customized Color-Keyed ® Connectors for Copper Cables • Standard and special tongue angles, stacking and non-stacking, bolt holes sizes and centers, protective platings. • Specially modified one and two hole copper Color-Keyed® compression lugs, Series 54100, 54200, 54850BE and 54930BE for flex and code copper stranded cables. Material high conductivity wrought copper. • Minimum order quantity: Standard package quantity by cable size. Consult factory for price and delivery. All customized lugs are made to order. A.R.O. Non-cancellable.
6
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
403030.01CK
3/11/02
3:28 PM
Page 8
COMPRESSION
Color-Keyed® Connectors Tongue Specifications – See Chart “A” For Dimensions Stud Sizes □ #8 □d □ #10 □e □b □f □j □g □c □ 1
Double Hole
Single Hole
Blank
Chart A Nominal Bolt Hole Size .015 #8 #10 b j c d e f *g *1
Hole Wrench Offset Clearance .030 Min.
.173 .204 .281 .344 .406 .531 .656 .812 .937 1.062
.200 .218 .250 .375 .375 .500 .812 .750 .875 .937
.240 .250 .312 .406 .440 .562 .875 .770 .890 1.000
#8 Code #8 Weld .406 .406 .469 .562 .578 – – – – –
#6 Code #6 Weld #4 Code .437 .437 .500 .562 .578 – – – – –
.562 .562 .562 .562 .594 – – – – –
#2 Code #4 Weld .593 .593 .593 .675 .675 .750 – – – –
Tongue Width Cable Size #1 Code 1/0 Code #2 Weld #1 Weld .672 .672 .672 .672 .672 .750 – – – –
.750 .750 .750 .750 .750 .750 – – – –
2/0 Code 1/0 Weld
3/0 Code 2/0 Weld
4/0 Code 3/0 Weld
250 Code
.825 .825 .825 .825 .825 .825 – – – –
.937 .937 .937 .937 .937 .937 .937 – – –
1.030 1.030 1.030 1.030 1.030 1.030 1.030 – – –
1.125 1.125 1.125 1.125 1.125 1.125 1.125 – – –
* These bolt holes available in one hole lug only.
Chart B Cable Size #8 #6 #4 #2 #1 1/0 2/0 3/0 4/0 250 300 350 400 500 600 700 750 800 900 1000
Tongue Thickness .080 .081 .099 .108 .106 .125 .125 .125 .137 .137 .153 .177 .173 .218 .244 .228 .270 .266 .313 .297
Straight Lug Barrel Length Plus Transition Short Long
Barrel O.D. I.D.
.635 .675 .685 .815 .825 .975 .965 1.085 1.255 1.375 1.900 2.090 2.460 2.670 2.900 2.784 3.050 3.213 3.450 3.356
.260 .296 .365 .410 .467 .571 .571 .632 .701 .766 .850 .926 .960 1.100 1.200 1.255 1.330 1.375 1.500 1.550
.935 .975 .985 1.115 1.275 1.325 1.315 1.435 1.705 1.925 2.675 2.896 2.980 3.610 3.490 3.925 4.550 4.500
.180 .215 .266 .302 .361 .396 .446 .507 .564 .629 .660 .720 .757 .852 .926 .997 1.030 1.079 1.145 1.203
Straight
Dim “X” Stacked Lugs 45°
90°
Dim “Y” Short Long
Dim “H” Short Long
.158 .134 .175 .216 .212 .250 .250 .250 .274 .274 .459 .531 .519 .654 .732 .684 .810 .800 .940 .890
.478 .544 .622 .649 .731 .789 .859 .946 1.031 1.123 1.226 1.333 1.370 1.514 1.630 1.662 1.745 1.728 1.900 2.070
.394 .432 .502 .535 .592 .646 .696 .757 .826 .891 .975 1.103 1.085 1.225 1.325 1.375 1.455 1.625 1.650 1.675
.595 .587 .637 .711 .710 .794 .829 .900 1.015 1.085 1.180 1.267 1.551 1.629 1.762 1.780 1.827 1.952 2.065 2.031
.779 .767 .838 .958 .956 1.075 1.125 1.225 1.387 1.487 1.924 2.096 2.484 2.669 2.897 3.011 3.050 3.213 1.387 1.487
.808 .799 .849 .923 1.028 1.042 1.077 1.148 1.333 1.474 1.726 1.830 1.913 2.266 2.147 2.434 2.787 2.787
1.079 1.067 1.138 1.258 1.406 1.425 1.475 1.575 1.837 2.037 2.679 2.896 2.984 3.619 3.497 3.925 4.554 4.506
Note: Stacking lugs are available for one bolt only. Consult Factory: Straight: 700 kcmil & up 45°: 400 kcmil & up 90°: 500 kcmil & up
8
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
403030.01CK
3/11/02
3:28 PM
Page 9
Color-Keyed® Connectors COMPRESSION
Formula 1 = (.125 + 2 (OD) + .037 – Tongue Thickness)
Chart C Tongue Width .030 Code Cable Size Bolt Hole Size
300 kcmil 4/0 Weld
350 kcmil
400 kcmil
500 kcmil 400 Weld
600 kcmil 500 Weld
1325/24
700 kcmil
750 kcmil
800 kcmil
900 kcmil
1000 kcmil
#8 #10 b j c d e f *g *1
– – 1.250 1.250 1.250 1.250 1.250 1.250 – –
– – 1.355 1.355 1.355 1.355 1.355 1.355 – –
– – 1.410 1.410 1.410 1.410 1.410 1.410 – –
– – 1.605 1.605 1.605 1.605 1.605 1.605 1.605 –
– – 1.745 1.745 1.745 1.745 1.745 1.745 1.745 1.745
– – 1.805 1.805 1.805 1.805 1.805 1.805 1.805 1.805
– – 1.840 1.840 1.840 1.840 1.840 1.840 1.840 1.840
– – 1.935 1.935 1.935 1.935 1.935 1.935 1.935 1.935
– – 2.010 2.010 2.010 2.010 2.010 2.010 2.010 2.010
– – 2.180 2.180 2.180 2.180 2.180 2.180 2.180 2.180
– – 2.265 2.265 2.265 2.265 2.265 2.265 2.265 2.265
© 2002 Thomas & Betts Corporation. Specifications are subject to change without notice.
www.tnb.com
9
