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

Preparation:
Safety first: Ensure all safety protocols are followed. Wear appropriate personal protective equipment (PPE) and ensure the transformer is de-energized.
Tools and materials: Have all the necessary tools and materials ready, including wire lugs, crimping tools, heat shrink tubing and insulation tape.
Stripping the cables:
Remove outer jacket: Carefully remove the outer jacket of the cable without damaging the inner insulation or conductors.
Strip insulation: Remove insulation from the ends of the conductors to expose the bare wire. The length of exposed wire should match the size of the cable lug.
Crimping the cable lugs:
Select appropriate cable lugs: Choose the right size and type of cable lugs for the conductors.
Crimping: Insert the stripped conductor into the eyelet and clamp it with a crimping tool. Make sure the connection is firm and secure to avoid loose connections.
Attaching shrink tubing:
Position the tubing: Slide the shrink tubing over the crimp eyelet and the exposed conductor.
Heat Application: Use a heat gun to shrink the tubing around the connection to provide insulation and protection from moisture and contaminants.
Connection to the transformer:
Preparing the connections: Clean the transformer terminals to ensure a good electrical connection.
Screw connection: Attach the crimp terminals to the transformer terminals using the appropriate screws and washers. Tighten the screws firmly to ensure a firm connection.
Insulation and protection:
Electrical tape: Wrap electrical tape around the connection points for additional insulation and protection.
Cable management: Secure cables with cable ties or clamps to prevent movement and reduce mechanical stress on connections.
Testing and verification:
Continuity test: Perform a continuity test to make sure the connection is not broken.
Insulation resistance test: Check the insulation resistance to ensure the integrity of the insulation.
Final inspection: Perform a final visual inspection to ensure that all connections are secure and properly insulated.
Restore power to the transformer:
Safety check: Make sure all tools and materials are removed from the work area.
Turning on: Turn the transformer back on and monitor the connections for signs of overheating or abnormal operation.

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