Introduction to the Installation Method of High-Current Terminals

1. Core installation principles
Clean: The contact surface must be kept clean and free of oxide layers, oil stains, and dust.
Flat: The contact surface should be flat and smooth, without burrs and pits.
Fastening: Use the correct torque for fastening, ensuring adequate contact pressure.
Matching: Terminals, wires, crimping tools/bolts must match specifications.
Heat Dissipation: Ensure that the terminals have proper heat dissipation conditions to avoid overheating.

2. Preparation before installation
Tools and Materials:
Torque Tools: The Most Critical Equipment! A calibrated torque wrench (electric or manual) must be used, and it is strictly forbidden to use a regular wrench to tighten by feel.
Contact Resistance Tester (Optional but Recommended): Used to verify installation quality.
Cleaning tools: fine sandpaper (such as 600# or above), anhydrous alcohol, non-woven fabric.
Contact resistance paste/power composite grease: used for copper-aluminum connections or outdoor/corrosive environments, note: not ordinary butter, products containing conductive fillers such as zinc powder are required.
Measuring tool: Vernier caliper (check wire cross-sectional area and terminal aperture).
Crimping tool (e.g. crimping terminals): Hydraulic or mechanical crimping pliers that match the terminals.
Personal protective equipment: insulated gloves, goggles.

Inspection and Cleaning:
Check the terminals and wires: Confirm that the rated current, voltage, and cross-sectional area of the wires match. Check that the terminal body is free of cracks and deformation.
Clean contact surfaces:
For copper or tinned terminals, if oxidized (darkened), lightly sand with fine sandpaper in the same direction until they reveal a metallic sheen, then clean and dry with alcohol. For silver-plated terminals, never sand and clean only with alcohol. Clean the wire splice (or the contact surfaces of the terminal strip or equipment terminals if it is a bolt hole terminal).

3. General installation steps (taking the most common bolted connection type as an example)
Step 1: Pre-treatment of wires
Depending on the stripping length required by the terminals, a special tool is used to strip the insulation to ensure no damage to the conductor.
For multi-strand strands, try to keep the stranded state and tighten it slightly. For oversized section wires, it is recommended to crimp them with a special nose (conduit) before connecting.

Step 2: Apply Conductive Paste (if applicable)
Apply a thin layer of power composite grease to the cleaned contact surfaces (inner wall of terminals, Wire Connectors, and wiring strip surfaces). The function is anti-oxidation, anti-corrosion, and filling micro-gaps. It should not be too thick.

Step 3: Insert and align
Insert the wire or crimped wire nose into the terminal terminal hole. Make sure the wire is fully inserted to the end, with no exposed conductors outside the pressure zone. Align the mounting holes and put in the washer (if any) and spring washer flat.

Step 4: Torque fastening
Using a torque wrench, tighten according to the official torque value provided by the terminal manufacturer. If data is not available, refer to similar product standards (but accurate data is strongly recommended).
Fastening sequence: For terminals with multiple bolts (such as two or four bolts), they should be tightened diagonally, crossed, and step-by-step.

Step 5: Final check
Visual inspection: no loose wires, no abnormal deformation of terminals, and bolts in place.
Feel check: Try to shake the wire gently, there should be no loose feeling.
Markings: If necessary, make fastened marks (such as drawing anti-movement lines).