Fully Insulated Connection Technology for Reliable Contact Protection

Unlike conventional caps that only cover the contact, Lugsulation provides full electrical insulation.
This all-around protection makes corrosion and creepage currents a thing of the past – and reliably eliminates the risk of short circuits.

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Lugsulation Variants at a Glance

Flex

Cap

Cap High

Cap Seal

Deep Low

Deep Smart

Angled

02 lug angled seitlich querschnitt

Curved

Key Benefits of the Lugsulation

Cost efficiency

Lugsulation helps lower your total cost of ownership by combining quick installation, maintenance-free operation, and long-lasting insulation performance.
It reduces system failures and eliminates the need for expensive repairs – making it a smart investment for sustainable efficiency.

On-Site Assembly

Lugsulation is tool-free and can be applied directly during cable assembly.
Its fast installation process reduces production time, making it suitable for both field installations and series manufacturing.

Fire protection

Lugsulation can be supplied in UL94 V0-rated flame-retardant material on request – making it suitable for safety-critical applications with strict fire protection standards.

Corrosion-Resistant Electrical Contacts

Full insulation reliably seals out moisture, preventing oxidation, terminal degradation, and power losses – even under demanding environmental conditions.

Touch protection

Lugsulation’s complete enclosure of the terminal offers effective touch protection, enhancing system safety and minimizing hazards for maintenance staff.

Low maintenance

Once installed, the connection remains permanently protected.
Lugsulation significantly reduces maintenance effort and extends the service life of electrical systems.

Lugsulation variants in detail

Lugsulation Flex

The standard solution for fully insulated connections

The Lugsulation Flex, featuring a sealing sleeve, insulation screw, and HSYS cable lug, provides a fully insulated connection and reliably protects the electrical contact point from accidental contact, moisture ingress, and corrosion.
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Lugsulation Cap

The compact solution with hexagon socket screw

For many Lugsulation variants where a standardized insulation screw with plastic head cannot be used for sealing, there is the option to use an ISK (Allen) screw instead. After tightening, a cap securely and permanently seals the screw opening.
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Lugsulation Cap High

The solution with increased sealing geometry

The Lugsulation Cap High is a variant of the Cap. Featuring a hexagon socket screw (ISK), optimized sealing geometry, and a copper ring, it provides reliable protection up to IP64 and is suitable for applications with specific spatial or geometric requirements.
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Lugsulation Cap Seal

Optimal solution with customized sealing surface

The Lugsulation Cap Seal is a variant of the Cap that combines optimized sealing geometry with a hexagon socket screw (ISK) and a copper washer to provide reliable protection up to IP64. Protruding connection areas are sealed radially and axially, preventing partial exposure that could lead to conductive or open sections susceptible to leakage currents or corrosion.
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Lugsulation Deep Low

For flat, low-profile connections

The Lugsulation Deep features a special Deep cable lug design with sealing adapted to the terminal, ensuring durable, corrosion-free contacts at low overall costs and with easy maintenance. It is designed for flat conductors where the contact area does not protrude.
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Lugsulation Deep Smart

The solution for flat and stackable connections

The Lugsulation Deep Smart provides complete insulation of flat contacts and, thanks to its stackable design, enables serial or parallel screw connections without additional components. With integrated sealing, Torx insulation screws, and a durable special rubber (also V0 rated according to UL94), it offers reliable protection and is ideally suited for lithium-ion batteries and compact electrical systems.
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Lugsulation Angled

The solution for confined installation spaces

The Lugsulation Angled provides complete insulation and protection in tight spaces. With 90°, 45°, and other cable outlet options, it enables precise cable routing, quick installation, and is suitable for lithium-ion batteries, complex systems, and especially for front-end terminals.
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Lugsulation Curved

The solution for tight and complex cable routing

The Lugsulation Curved provides complete insulation and reliable protection over the contact in electrical systems. With its curved cable outlet, it allows flexible installation, optimal use of space, and is ideally suited for batteries, converters, compact machines, and complex systems.
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Lugsulation in Practice

Motor Technology

Robust connection solutions for autonomous agricultural machinery that must operate reliably in demanding environments. Perfectly suited for modern electric and hybrid systems in agriculture, exposed to dirt, moisture, and other environmental influences.

Inverter Technology

High-quality connection technologies for stationary energy storage systems and mobile industrial battery applications. Lugsulation provides protection against corrosion, accidental contact, vibration, and leakage currents – making it ideal for all areas of industrial energy storage.

Transport Systems

Autonomous systems are only truly autonomous if they don’t require constant maintenance. Corroding connections have no place here.

...and Much More!

Efficient and durable connection components, for example for electric industrial trucks, adaptable to nearly any application. Our products improve energy efficiency and keep your vehicles running longer with minimal downtime.

The components of lugsulation

The lugsulation is a set consisting of a sealing sleeve, a specially manufactured cable lug, and an insulation screw.

Sealing sleeve

Provides reliable protection against moisture, dirt, vibrations, and corrosion—even under extreme operating conditions.

 

Special cable lug

  • For Flex and Cap: Special HSYS cable lug
  • For Smart: Deep cable lug, also stackable for flat contacts

Screw (optional)

  • Flex: Insulation screw (standard)
  • Cap: ISK (Allen) screw
  • Smart: Torx screw

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Frequently Encountered Issues

Leakage current, short circuits, contact corrosion – there can be many troubles caused by insufficient insulated contacts. We have got the solutions!

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Real-World Use Cases

Insufficient insulation of live contacts is a common and cross-industry issue. Subsequent risks are performance fail up to complete system collapse.

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Interested in learning more about our Lugsulation system?

We always think one step ahead. Reach out to discover how our solutions can support your battery and terminal applications.
As your reliable partner in connection technology, we’re here to help – contact us today.

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