Cable Lugs, choose a size!

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Cable Lugs are the terminations that are attached to the ends of cable. There are two sizes which need to be considered.
  1. Hole Size. This refers to a straight forward diameter, and is the diameter of the bolt on which the lug will be bolted (8mm in the diagram)
  2. Cable Size. This is the confusing one. The size refers to the Cross Sectional Area of the cable, not the diameter (10mm^2 in the diagram)









The reason for this apparent problem, is that cable manufacturers produce cables in different shapes. Round, triangular, multi-strand, solid etc. The current that can be carried is directly related to the cross section of the cable, so regardless of the shape, they will give its size as the area.
The cable size can be found printed on the cable, along with its BS or EN number. If you find this, then you know your cable size, and can choose a lug to suit. If not, keep reading.
Most cables are standard sizes, so if you have cable which is "round" in cross section, here is a chart of diameters (easy to measure) against standard sizes, (CSA, not so easy to measure), Remember though that to get a good fit, you will be squeezing the lug onto the cable, you need the cable to go in reasonably easily, which is why the opening is a bit bigger!
Diameter Cable Size (cross sectional area, standard size mm^2)
Cable diameters/ standard sizes
measure with calipers, or as close as possible with a ruler Your Lug size will be (actual measured diameter of lug is in brackets)
0.75mm 1.00
1.4mm 1.5
1.75mm 2.5
2.75mm 6.0
3.6mm-4.4mm 10.0 (4.5mm diameter)
4.5mm-5.5mm 16.0 (5.7mm diameter)
5.6mm-6.6mm 25.0 (6.8mm diameter)
6.7mm-8.5mm 35.0 (8.6mm diameter)
8.0mm-9.3mm 50.0 (9.5mm diameter)
9.4mm-10.5mm 70.0 (11mm diameter)
11mm-12.5mm 95.0 (13mm diameter)
The above sizes are as close as you are likely to be able to measure, so if for example, you have stranded cable, and it measures 10mm in diameter, it is most likely to be a 70mm^2 cable ( nearest we have from the chart is 9.4mm diameter, but we know stranded cable has tiny gaps, so it is probably this one)
This picture might make it clearer, it shows Solid and Stranded 70mm^2 cable, and shows how the diameter will alter slightly.









And of course, if you stll have problems, you can always ask us, we will do our best to help
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