HEX Bimetallic Aluminium-Copper Connectors (Splices) – 16 to 240 sq mm

HEX aluminium-copper bi-metal connectors (HBS) join an aluminium cable to a copper cable in a straight line. EC-grade copper is friction-welded to EC-grade aluminium and then machined to size, so each conductor is crimped into a barrel of its own metal. Sizes run from 16 to 240 sq mm on each side, and HEX also makes bimetallic connectors to customer specifications, samples or drawings. A HEX bimetallic connector has been electrically and mechanically tested by PSB Corporation, Singapore. Made by HEX, the brand of Brass Copper & Alloy (I) Ltd., Mumbai — an ISO 9001 company whose products are tested by CPRI (India), UL (USA), KEMA (Netherlands) and SIRIM (Malaysia).

At a glance

• Use: aluminium cable to copper cable, straight joint
• Construction: EC-grade copper friction-welded to EC-grade aluminium, machined
• Range: HBS 16-16 to HBS 240-240 (copper side – aluminium side)
• Finish: uncoated or electro-tinned copper
• Test: electrical and mechanical tests, PSB Corporation (Singapore)

Why a bimetallic connector

• Correct metal for each conductor — no galvanic joint between cable and barrel.
• Friction-welded interface.
• Size combinations from 16-16 to 240-240, including reducing pairs.
• Made to order to your specification or sample.

Specifications

• Equal sizes: HBS 16-16, 25-25, 35-35, 50-50, 70-70, 95-95, 120-120, 150-150, 185-185, 240-240
• Reducing pairs: HBS 25-16, 35-16, 35-25, 50-25, 50-35, 70-35, 70-50, 95-50, 95-70, 120-70, 120-95, 150-95, 150-120, 185-120, 185-150, 240-150, 240-185
• Overall length (J): 75 mm (16-16) to 132 mm (240-240)
• Copper barrel depth: 25–50 mm
• Aluminium barrel depth: 40–60 mm

Where it is used

• Joining aluminium and copper cables in distribution networks
• Extensions where an old copper cable meets a new aluminium one
• Service and feeder connections

Which HEX aluminium termination do I need?

• Aluminium lugs and through connectors — general-purpose Al terminations, 16–300 sq mm.
• Long barrel Al lugs for XLPE — heavy duty, 25–1000 sq mm.
• DIN 46329 Al lugs — barrier design with oil stop, 25–500 sq mm.
• Sector lugs and ferrules — for 3- and 4-core sector-shaped conductors.
• Bimetallic lugs — aluminium cable onto copper busbar.
• Mechanical connectors — screw-clamp, no crimping tool needed.

Related products

• HEX bimetallic Al-Cu lugs
• HEX copper in-line connectors
• HEX aluminium splices for LV & MV

Frequently asked questions

What does a bimetallic connector join?

An aluminium cable to a copper cable, in a straight line.

How is it made?

EC-grade copper is friction-welded to EC-grade aluminium and machined to size.

Can I join different sizes?

Yes — reducing combinations such as HBS 240-185 are standard.

Can you make special sizes?

Yes — to customer specifications, samples or diagrams.

Where can I buy HEX cable lugs in India?

From Jai Enterprises, which supplies HEX cable lugs, terminals and connectors across India from Bhilai and Raipur, Chhattisgarh. Call +91 9340081159 with the product codes or cable sizes and quantities.

How to order

Supplied by Jai Enterprises, despatched from Bhilai and Raipur, Chhattisgarh, to sites across India. To request a price, call +91 9340081159 or send an enquiry from this page with your quantity and site details, and we will confirm availability, lead time and the right model for the job.