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Changzhou Fenglan New Materials Co., Ltd.

High Voltage Cable Terminal

-- Steady & Reliable Manufacturer --

High Voltage Cable Terminal Overview

A high voltage cable terminal is a purpose-engineered lug or end connector that terminates medium- and high-voltage power cables — typically rated from 1 kV up to 110 kV — onto switchgear, transformer bushings, circuit breakers, and cable joints. Unlike standard crimp lugs used in low-voltage wiring, HV cable terminals must manage electric field stress at the cable screen cut-back point to prevent partial discharge and premature insulation failure.

Fenglan supplies compression-type (hex crimp) and mechanical-type (bolted) HV cable terminals for XLPE and EPR insulated cables from 16 mm² to 630 mm² conductor cross-section, rated from 3.6/6 kV to 64/110 kV. All products comply with IEC 60502-4 and include stress-control elements where required by voltage class.

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Specification

Voltage Rating3.6/6 kV, 8.7/15 kV, 12/20 kV, 18/30 kV, 26/45 kV, 64/110 kV (U0/U)
Conductor Cross-Section16 mm² – 630 mm²
Cable Type CompatibilityXLPE, EPR, and paper-insulated (PILC) cables
Terminal TypeCompression (hex crimp) or mechanical (bolted lug)
Conductor MaterialElectrolytic copper (standard); aluminium (specify AL grade)
Lug MaterialElectrolytic copper, tin-plated; bimetallic CU/AL for aluminium cables
Stress ControlGeometric stress cone (12 kV+); cold-shrink or heat-shrink stress tube included
Installation MethodHydraulic compression crimper or torque-wrench bolted connection
Operating Temperature–40 °C to +90 °C (continuous); 250 °C (short-circuit)
StandardsIEC 60502-4, IEC 61238-1, IEEE 404, CE, RoHS
TestingImpulse withstand, AC withstand, partial discharge < 10 pC at 1.73 × U0
MOQ10 sets; 2 sets sample

Application

  • Utility power distribution networks — terminating underground XLPE feeder cables at pole-mounted and ground-level distribution transformers up to 36 kV
  • Primary substation switchgear — cable-to-busbar connections in metal-clad and GIS switchgear rated 12 kV to 110 kV
  • Wind turbine tower cable systems — MV export cable termination at tower base ring main units and offshore platform switchboards
  • Solar farm MV collection systems — XLPE feeder cable termination at combiner stations and main step-up transformers
  • Railway traction substations — 25 kV AT and BT system cable termination on traction transformers and sectioning cabins
  • Industrial HV motor and generator connections — stator winding lead termination and cable box connections on medium-voltage motors up to 11 kV
  • Data centre and large campus power infrastructure — MV underground cable ring main termination supplying main LV distribution transformers

Advantage

  • Partial discharge below 10 pC — geometric stress cone design and precision-moulded stress-control elements maintain the electric field below the partial discharge inception voltage, preventing insulation degradation at the screen cut-back — the most common failure point in HV cable terminations
  • Cold-shrink and heat-shrink options — cold-shrink kits install without a heat gun, eliminating fire risk in gas-filled switchgear rooms; heat-shrink kits offer a lower material cost for outdoor and open-air installations
  • Bimetallic CU/AL lugs available — friction-welded copper-to-aluminium lugs allow aluminium-conductor cables to terminate directly on copper bus-bars without galvanic corrosion risk, without additional adapters
  • IEC 61238-1 compression-tested — all crimp barrels are type-tested for electrical resistance, mechanical pull-out force, and thermal cycling to IEC 61238-1 Class A, the most stringent compression terminal standard
  • Short-circuit rated to 250 °C — the copper lug and crimp barrel withstand the short-circuit temperature limit of XLPE cables without mechanical failure or increased contact resistance
  • Full accessory kit supplied — each terminal set includes stress tubes, semi-conductive tape, insulating tape, copper braid earth bonding, and installation instructions, eliminating the need to source ancillary materials separately

Payment & Shipping

We accept T/T (bank transfer), L/C at sight, PayPal (samples), and Western Union. A 30% deposit is required to confirm production, with the balance paid before shipment.

Standard lead time is 7–15 business days for regular orders; prototype samples ship within 3–5 days. We ship worldwide via DHL, FedEx, UPS, sea freight (FCL/LCL), and air freight. FOB Changzhou and CIF terms are both available. All goods are packed in export-standard cartons with foam padding or wooden crates for heavy items. A commercial invoice, packing list, and COA are provided with every shipment. For large OEM orders, customized packaging and private-label options are available upon request.

  • Q: What is a stress cone and why is it needed on HV cable terminals?
  • A: At the point where the cable screen (earthed metallic layer) is cut back during termination, the electric field concentrates into a very small area, which can cause partial discharge and ultimately puncture the insulation. A stress cone — made from geometrically shaped semi-conductive rubber or heat-shrink material — redistributes this field concentration over a longer, smoother profile, keeping the field below the partial discharge threshold. Terminals above 3.6/6 kV require a stress cone by design; lower-voltage terminals do not.
  • Q: What hydraulic crimping force is required for HV cable lug compression?
  • A: The required crimp force depends on the lug barrel cross-section and the die profile specified by the terminal manufacturer. As a guide, conductors up to 150 mm² typically require 60–80 kN; 150–400 mm² requires 100–120 kN; 400–630 mm² requires 150 kN or more. Always use the die set specified in our installation instruction — using an incorrect die produces an incomplete crimp that fails IEC 61238-1 pull-out requirements.
  • Q: Can HV cable terminals be used both indoors and outdoors?
  • A: HV cable terminations come in two configurations: indoor (for use inside switchgear, transformer boxes, and cable boxes where the terminal is protected from weather) and outdoor (for open-air use, incorporating a porcelain or silicone rubber shed housing to provide the required creepage distance and rain performance). Using an indoor terminal outdoors will result in tracking and flashover on the exposed insulation surface. Always specify the installation environment when ordering.
  • Q: What is the difference between a compression lug and a mechanical (bolted) lug for HV cables?
  • A: A compression lug is crimped onto the cable conductor using a hydraulic die set, producing a permanent gas-tight joint with the lowest contact resistance and highest pull-out strength — preferred for permanent installations. A mechanical (bolted) lug uses set-screws or wedge bolts to clamp the conductor, allowing the cable to be removed and re-terminated without cutting. Mechanical lugs are used in test facilities, maintenance terminals, and locations where cables are regularly disconnected for testing or switching.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
Changzhou Fenglan New Materials Co., Ltd.
ABOUT US
Quality is Our Core Competitiveness
Changzhou Fenglan New Materials Co., Ltd.
Founded in 2010, As China High Voltage Cable Terminal Manufacturers and High Voltage Cable Terminal Company. we are dedicated to manufacturing precision parts for automotive, industrial, and electrical applications. Backed by advanced manufacturing and R&D, we provide high-quality products and trusted solutions to our clients. We provide a wide selection of components to meet diverse industry needs: Electric Shafts: Drive shafts, coil motor shafts, servo motor shafts, water pump motor shafts, industrial motor shafts, and magnetic levitation motor shafts. Hardware: Precision parts for medical equipment, water heater coils, plumbing fittings, and various gas springs. Our commitment is to support our customers with reliable performance and long-term value.
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