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Low Voltage (LV) Cable Termination in Transformers: A Step-by-Step Guide
Proper termination of low voltage cables in transformers is crucial for ensuring safe and efficient electrical connections. Here’s a detailed process to guide you through the termination:

Preparation:
Safety First: Ensure all safety protocols are followed. Wear appropriate personal protective equipment (PPE) and verify that the transformer is de-energized.
Tools and Materials: Gather all necessary tools and materials, including cable lugs, crimping tools, heat shrink tubing, and insulation tape.
Cable Stripping:
Remove Outer Sheath: Carefully strip the outer sheath of the cable without damaging the inner insulation or conductors.
Strip Insulation: Strip the insulation from the ends of the conductors to expose the bare wire. The length of the exposed wire should match the size of the cable lug.
Crimping the Cable Lugs:
Select Appropriate Lugs: Choose the correct size and type of cable lugs for the conductors.
Crimping: Insert the stripped conductor into the lug and use a crimping tool to secure it. Ensure a tight and secure connection to avoid any loose contacts.
Applying Heat Shrink Tubing:
Position Tubing: Slide heat shrink tubing over the crimped lug and the exposed conductor.
Heat Application: Use a heat gun to shrink the tubing around the connection, providing insulation and protection against moisture and contaminants.
Connecting to the Transformer:
Terminal Preparation: Clean the transformer terminals to ensure a good electrical connection.
Bolt Connection: Attach the crimped lugs to the transformer terminals using appropriate bolts and washers. Tighten the bolts securely to ensure a firm connection.
Insulation and Protection:
Insulation Tape: Wrap insulation tape around the connection points to provide additional insulation and protection.
Cable Management: Secure the cables using cable ties or clamps to prevent movement and reduce mechanical stress on the connections.
Testing and Verification:
Continuity Test: Perform a continuity test to ensure there are no breaks in the connection.
Insulation Resistance Test: Check the insulation resistance to verify the integrity of the insulation.
Final Inspection: Conduct a final visual inspection to ensure all connections are secure and properly insulated.
Re-energizing the Transformer:
Safety Check: Ensure all tools and materials are removed from the work area.
Power On: Re-energize the transformer and monitor the connections for any signs of overheating or abnormal operation.