1
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Catalog 82020 Revised 11-02
Product Facts
Bar Crimp Technique
■Terminals and Splices for
aluminum-to-aluminum and
aluminum-to-copper strip-
ped wire applications
■Terminates stripped, strand-
ed and solid (round or rec-
tangular) aluminum and
copper conductors— indi-
vidually or in combination
■Eliminates messy inhibitors
■Available for a broad range
of wire sizes— from 16 AWG
to 500 MCM [1.25 to 253
mm2]
■Low cost, reliable termi-
nations provide stable
electrical and mechanical
performance
■UL 486B Listed where indi-
cated (see page 4) 1
1Bar crimp only
Insulation Piercing Technique
■Terminals and splices for
aluminum-to-aluminum,
copper-to-copper and alu-
minum-to-copper wire
applications
■Terminates film insulated
solid aluminum, film insu-
lated solid copper, or un-
insulated stranded copper
conductors — individually or
in combination
■Stripping of film insulated
solid conductors not
required
■Eliminates messy inhibitors
■Available for a broad range
of wire sizes — from 16 to
4/0 AWG [1.25 to 105 mm2]
■Copper body construction
■Low cost, reliable termi-
nations provide stable
electrical and mechanical
performance
Catalog 82020
Revised 11-02
2
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Introduction
The Bar Crimp
© Copyright 1972, 1973, 1974, 1984,
1992, 1993,1994 and 2002 by Tyco
Electronics Corporation.
All Rights Reserved.
AMP, AMP FAX, COPALUM,
CERTI-CRIMP, DYNA-CRIMP and TYCO
are trademarks.
The AMP family of COPALUM terminals and splices provides reliable, low cost termina-
tions for both aluminum and copper wire. Stranded, solid, round and rectangular
conductors, individually or in combinations falling within a specified CMA range, can be
terminated in the same wire barrel. Also, the same terminals and splices can be crimped
to either uninsulated wire, using a bar crimp configuration or with the insulation piercing
technique, to film insulated wire. Prestripping of conductors is not required. Because of
this versatility, AMP COPALUM products are finding wide usage wherever aluminum wire
is being used for its weight and cost savings advantages.
COPALUM terminals and splices are available for terminating a broad range of wire sizes:
16 AWG to 500 MCM [1.25 to 253 mm2] using the bar crimp technique, and 16 to 4/0 AWG
[1.25 to 105 mm2] using the insulation piercing method. Each product features a copper
body construction and employs a perforated copper alloy liner. This construction, coupled
with the AMP crimp, produces electrically and mechanically stable connections by over-
coming the inherent problems of aluminum oxide penetration and reformation, cold flow,
creep, corrosion and thermal expansion (common in aluminum-to-copper applications).
The bar crimp technique employs the principle of high crimp deformation to achieve
electrically and mechanically reliable terminations. During crimping, the relatively soft alu-
minum conductor is extruded through the liner perforations, breaking brittle aluminum
oxides and allowing clean aluminum metal to be brought into direct contact with the liner
and the wire barrel. Due to the crimp’s tight configuration, reforming of aluminum oxides,
as well as the formation of other corrosive films, is minimized. When crimping standard
conductors, this high deformation breaks up the oxides that surround each individual
strand and brings the strands into direct contact with each other, creating possible inter-
strand bonds or cold welds among strands. Because of the large number of independent
contact surfaces, the total contact area is increased, thus reducing the possibility of
electrical failure due to thermal expansion, creep and corrosion.
The mechanical characteristics of the termination are achieved through a secondary por-
tion of the crimp which reduces, by a predetermined amount, the cross sectional area of
the termination. The reduction is totally independent of the wire type, size and shape as
long as the wire(s) being terminated fall within the appropriate CMA range. Termination
reliability is further enhanced by the fact that inhibitors are not required. Subsequently,
COPALUM terminals and splices using the bar crimp method are highly adaptable for
oil-filled transformer use.
When three or more rectangular conductors are being crimped, they should be inserted
on edge. They should not be inserted to permit the electrical and mechanical crimps to be
positioned across the width of the connector.
Cross Section of
Bar Crimp Cross Section of
Insulation Piercing Crimp
Catalog 82020
Revised 11-02
3
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
The insulation piercing crimp technique uses its specific crimp configuration and the per-
forated design of the terminal or splice liner to break down the film insulation and establish
an electrical interface between the conductor and terminal or splice body. During crimping,
the film insulated conductor is extruded into the perforated liner, causing the film insulation
to be sheared. This produces a hermetically sealed interface between the connector and
the body of the terminal or splice. An adequate surface contact area is achieved due to
the high density hole pattern of the liner. Because of the hermetic seal, products using the
insulation piercing crimp can be exposed to the gaseous and oil environments found in oil
and air cooled transformers or air and Freon cooled motors.
A secondary crimp section provides the mechanical properties of the termination (tensile
strength, vibration, resistance, flex life, etc.). This secondary crimp flanks the electrical
crimp, establishing optimum mechanical characteristics on both sides of the electrical
crimp. Such a crimp design permits either parallel, butt or pigtail splicing. The crimp
design also allows solid copper, solid aluminum and stranded copper to be terminated in
the same wire barrel if certain restriction regarding size, number and total CMA of conduc-
tors being terminated are observed as follows:
1. In a solid (or combination of solids) aluminum and stranded copper application, the
maximum amount of CMA fill for the copper conductor should not exceed 40% of the
total CMA being crimped.
2. Up to a maximum of 10 equal size round conductors may be crimped without insulation
removal.
3. Up to a maximum of 6 equal square conductors may be crimped without insulation
removal.
4. Four rectangular conductors where T ≥ 1/4W or 2 rectangular conductors where
T ≤ 1/4W may be crimped without insulation removal.
5. Due to the physical size limitations of the wire barrel, it may not be possible for a partic-
ular CMA loading to physically fit in the normally recommended connector. In these
instances where 7 or more equal round conductors or a combination of solid aluminum
and stranded copper is used, and the total CMA is at least 50% of the maximum CMA
of the next larger size connector, this larger size connector may be used with its appro-
priate crimping die.
6. When crimping different size solid conductors, size should not vary by more than 1 wire
gauge, and preferably by no more than 1/2 wire gauge.
Tooling available for terminating COPALUM terminals and splices using the insulation
piercing crimp includes the DYNA-CRIMP tool for wire sizes 8 through 4/0 AWG [8 through
105 mm2], pneumatic tooling for wire sizes 16-14 through 6 AWG [1.25-2 through 15 mm2]
and manually operated hand tools for wire sizes 16-14 AWG [1.25-2 mm2] and 12-10 AWG
[2-6 mm2].
The Insulation
Piercing Crimp
Technical Documents
Test Reports:
110-13506
Product Specification:
108-13013
Application Specification:
114-02121
Warning: Not approved for reconnection of residential aluminum
branch circuit wiring. (Refer to Catalog #82205.)
Catalog 82020
Revised 11-02
Testing Data
4
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Test Results of Insulation Piercing
Crimp Terminations
Current Cycling: Under oil at 1375 amperes, AC
Products Tested: COPALUM splices, wire size 250 MCM [127 mm2]
Pressure Type Wire/Connector Reference Chart
AMP Wire Range UL Listed File E13288 Connector Marking Copper Wire Size Strip Length
and Aluminum Wire Size Nominal
AWG mm2AWG mm2AWG mm2AWG mm2inch mm2
12-10 3-6
10-16 1.25-6 Solid Aluminum 16-14 1.25-2 18-14 0.8-2 5/16 7.94
Solid or Stranded 14-10 2-6
Copper or Aluminum Solid or 12-10 3-6 14-10 2-6 3/8 9.53
Stranded Copper 8 8 10-8 5-8
6 14 8-6 8-14 7/16 11.11
4 21 6-4 14-21 19/32 15.08
2 35 4-2 21-35
1/0 50 2-1/0 35-50
8-500 MCM 8-253 8-500 MCM 8-253 2/0 70 1/0-2/0 50-70 3/4 19.05
Solid or Stranded Stranded Aluminum 3/0 85 2/0-3/0 70-85
Aluminum or Copper or Copper 4/0 105 3/0-4/0 85-105 25/32 19.64
250 MCM 127 4/0-250 MCM 105-127 1-3/16 30.16
300 MCM 152 250-300 MCM 127-152 1-5/16 33.34
400 MCM 203 300-400 MCM 152-203 1-7/16 36.51
500 MCM 253 400-500 MCM 203-253 1-9/16 39.69
Notes: Perforated liner must be present in wire barrel.
Thermal Shock: 0.5 hr. @ +150°C & –55°C per cycle; 15 amperes,
DC
Products Tested: COPALUM terminals wire size 8 AWG
[8 mm2] (terminal-to-terminal readings include two terminations
plus 4 in. [101.6 mm] of conductor length).
Current Cycling: 100 cycles @ 35 amperes, AC; each cycle con-
sisting of 15 min. “on current” and 15 min. “off current”
Thermal Shock: 0.5 hr. @ +150°C and 0.17 hr. in ice water per
cycle; 5 amperes, DC
Products Tested: COPALUM parallel splices, wire size 8 AWG
[8 mm2] using two 14 AWG [2 mm2] solid aluminum conductors
(unstripped) and one 14 AWG [2 mm2] stranded copper wire con-
ductor (stripped). Graph curves represent individual conductor
readings.
Test Results of
Bar Crimp Terminations
Tongue Dimensions Part Numbers
Wire Size Thickness Stud Heads for
[mm2]Max. Size W L E C Hand Pneumatic Tools* Terminal
Circular Mils Max. Max. Min. Tool* 6-26 68068
16-14 .033 1/4 .531 1.107 .839 .564 68041-1—52587-1
[1.25] 0.84 M6 13.49 28.12 21.31 14.33 68140-1189447-1 68100
2050-5180 6 .375 .835 .645 .302 68042-1— 68105 51979-1
M3.5 9.53 21.21 16.38 7.67 68141-1 189444-1 68100, 68101
8 .375 .835 .645 .302 68042-1— 68105 51979-1
M4 9.53 21.21 16.38 7.67 68141-1 189444-1 68100, 68101
12-10 .042 10 .375 .835 .645 .302 68042-1— 68105 51979-2
[5.0] 1.07 — 9.53 21.21 16.38 7.67 68141-1 189444-1 68100, 68101
5180-13100 1/4 .375 .835 .645 .302 68042-1— 68105 51979-3
M6 9.53 21.21 16.38 7.67 68141-1 189444-1 68100, 68101
1/4 .593 1.173 .874 .531 68042-1— 68105 52590-1
M6 15.06 29.79 22.2 13.49 68141-1 189444-1 68100, 68101
5/16 .593 1.173 .874 .531 68042-1— 68105 52590-2
M8 15.06 29.79 22.2 13.49 68141-1 189444-1 68100, 68101
*First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
Catalog 82020
Revised 11-02
Ring Tongue Terminals
5
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Tongue Dimensions Part Numbers
Wire Size Thickness Stud Heads for Heads & Die Inserts
[mm2]Max. Size W L E R Pneumatic Tools* for Power Unit 69120* Terminal
Circular Mils Max. Max. Max. 6-26 69015 68068 Head Die Insert
10 .500 1.384 1.131 .560 — 68032 68105 69099 68043 150720-1
— 12.7 35.15 28.73 14.22 1320369-1** 68081 68101, 68192-1 69099 68084
81/4 .500 1.384 1.131 .560 — 68032 68105 69099 68043 150720-1
[8.0] .048 M6 12.7 35.15 28.73 14.22 1320369-1** 68081 68101, 68192-1 69099 68084
13100-20800 1.22 5/16 .625 1.446 1.131 .560 — 68032 68105 69099 68043 150720-2
M8 15.88 36.73 28.73 14.22 1320369-1** 68081 68101, 68192-1 69099 68084
10MM .625 1.446 1.131 .560 — 68032 68105 69099 68043 184076-1
— 15.88 36.73 28.73 14.22 1320369-1** 68081 68101, 68192-1 69099 68084
10 .500 1.415 1.162 .580 — 69999 68106 69099 68044 150719-1
— 12.7 35.94 29.51 14.73 — 68082 68102 69099 68085
1/4 .500 1.415 1.162 .580 — 69999 68106 69099 68044 150719-1
M6 12.7 35.94 29.51 14.73 — 68082 68102 69099 68085
6.051 5/16 .679 1.504 1.162 .580 — 69999 68106 69099 68044 150719-2
[14] 1.30 M8 17.25 38.2 29.51 14.73 — 68082 68102 69099 68085
20800-33100 3/8 .679 1.504 1.162 .580 — 69999 68106 69099 68044 150719-3
— 17.25 38.2 29.51 14.73 — 68082 68102 69099 68085
10MM .679 1.504 1.162 .580 — 69999 68106 69099 68044 184079-1
— 17.25 38.20 29.51 14.73 — 68082 68102 69099 68085
*First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
**Requires Hand Actuated Power Unit Part No. 189721-2 or Foot Actuated Power Unit Part No. 189722-2.
Wire Size Range:
Aluminum – AWG 16 to 10
[1.25 to 5.0 mm2], CMA 2,050 to 13,100
Wire Size Range:
Aluminum – AWG 8 to 6
[8.0 to 14 mm2], CMA 13,100 to 33,100
Catalog 82020
Revised 11-02
Ring Tongue Terminals (Continued)
6
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Wire Size Range:
Aluminum – AWG 4 to 500 MCM
[21 to 253 mm2], CMA 33,100 to 600,000
Tongue Dimensions Part Numbers
Wire Size Thickness Stud Heads for Heads & Die Inserts
[mm2]Max. Size W L E R Pneumatic Tools* for Power Unit 69120* Terminal
Circular Mils Max. Max. Max. 69015 68068 Head Die Insert
10 .531 1.630 1.362 .625 68038 68045 150717-1
— 13.49 41.4 34.59 15.88 — —69099 68086
1/4 .531 1.630 1.362 .625 68038 68045 150717-1
M6 13.49 41.4 34.59 15.88 — —69099 68086
45/16 .531 1.630 1.362 .625 68038 68045 150717-1
.060 M8 13.49 41.4 34.59 15.88 — —69099 68086
[21] 1.52 3/8 .675 1.702 1.362 .625 68038 68045 150717-3
33100-52600 — 17.15 43.23 34.59 15.88 — —69099 68086
1/2 .675 1.702 1.362 .625 68038 68045 150717-5
— 17.15 43.23 34.59 15.88 — —69099 68086
10MM .675 1.702 1.362 .625 68038 68045 184082-1
— 17.15 43.23 34.59 15.88 — —69099 68086
1/4 .675 1.859 1.541 .625 68046 151982-1
M6 17.15 47.22 39.14 15.88 — — 69099 68130
5/16 .675 1.859 1.541 .625 68046 151982-1
2M8 17.15 47.22 39.14 15.88 — — 69099 68130
[35] .060 3/8 .675 1.859 1.541 .625 68046 151982-2
52600-83700 1.52 — 17.15 47.22 39.14 15.88 — — 69099 68130
1/2 .807 1.925 1.541 .625 68046 151982-3
— 20.5 48.9 39.14 15.88 — — 69099 68130
10MM .807 1.925 1.541 .625 68046 184084-1
— 20.49 48.89 39.14 15.88 — — 69099 68130
1/4 .675 1.859 1.541 .625 68047 151986-1
M6 17.15 47.22 39.14 15.88 — — 69099 68131
5/16 .675 1.859 1.541 .625 68047 151986-1
1/0 M8 17.15 47.22 39.14 15.88 — — 69099 68131
[50] .073 3/8 .675 1.859 1.541 .625 68047 151986-2
83700-119500 1.85 — 17.15 47.22 39.14 15.88 — — 69099 68131
1/2 .807 1.925 1.541 .625 68047 151986-3
— 20.5 48.9 39.14 15.88 — — 69099 68131
10MM .807 1.925 1.541 .625 68047 184087-1
— 20.49 48.89 39.14 15.88 — — 69099 68131
5/16 .926 1.930 1.560 .625 68048 151989-1
M8 23.52 49.02 39.62 15.88 — — 69099 68132
2/0 3/8 .926 1.930 1.560 .625 68048 151989-2
[70] .083 — 23.52 49.02 39.62 15.88 — — 69099 68132
119500-150500 2.11 1/2 .926 1.930 1.560 .625 68048 151989-3
— 23.52 49.02 39.62 15.88 — — 69099 68132
10MM .926 1.930 1.560 .625 68048 184090-1
— 23.52 49.02 39.62 15.88 — — 69099 68132
7/16 1.020 2.112 1.645 .625 68049 151992-2
3/0 — 25.91 53.64 41.66 15.88 — — 69099 68133
[85] .094 1/2 1.020 2.112 1.645 .625 68049 151992-3
150500-190000 2.39 — 25.91 53.64 41.66 15.88 — — 69099 68133
10MM 1.020 2.112 1.645 .625 68046 184092-1
— 25.91 53.64 41.66 15.88 — — 69099 68130
—
1/2 1.087 2.178 1.676 .625 69099 318106-1 151995-2
4/0 — 27.61 55.32 42.57 15.88 — — 69082 68050
[105] .105 68129
190000-231000 2.67 69099 —
10MM 1.087 2.178 1.676 .625 318106-1 184094-1
— 27.61 55.32 42.57 15.88 — — 69082 68050
68129
250 MCM .130 1/2 1.426 2.602 1.987 .625 69082 152559-4
[127] 3.30 M12 36.22 66.09 50.47 15.88 — — 68034
23100-300000
300 MCM .140 1/2 1.535 2.671 2.056 .625 152558-4
[152] 3.56 M12 38.99 67.84 52.22 15.88 — — 69082 68035
300000-380000
400 MCM .158 1/2 1.738 2.790 2.175 .625 152568-4
[203] 4.01 M12 44.15 70.87 55.25 15.88 — — 69082 68036
380000-478000
500 MCM .182 1/2 2.004 3.187 2.447 .750 152569-4
[253] 4.62 M12 50.9 80.95 62.15 19.05 — — 69082 68037
478000-600000
*First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
Wire Size Dim. Part Numbers
[mm2]LHeads for Tooling for
Circular MIls Max. Pneumatic Tools* Power Unit 69120* Splice
Aluminum Copper 6-26 69015 68068 Head Die Insert*
8 12-10 1.195 — 68032 68105 69099 68043 51826
[8.0] [5.0] 30.35 1320369-1** 68081 68101,68192-1 68084
13100-20800 5180-13100
6 8 1.340 69999 68106 69099 68044 51941
[14] [8.0] 34.04 —68082 68102 68085
20800-33100 13100-20800
4 6 1.630 69099 68045 51942
[21] [14] 41.4 —68038 —68086
33100-52600 20800-33100 —
2 4 1.995 69099 68046 52007
[35] [21] 50.67 ——— 68130
52600-83700 33100-52600
1/0 2 1.985 69099 68047 52010
[50] [35] 50.42 ——— 68131
83700-119500 52600-83700
2/0 1/0 1.985 69099 68048 52013
[70] [50] 50.42 ——— 68132
119500-150500 83700-119500
3/0 2/0 1.985 69099 68049 52016
[85] [70] 50.42 ——— 68133
150500-190000 119500-150500
4/0 3/0 —
[105] [85] 1.985 ———69099 318106-1 52019
190000-231000 150500-190000 50.42 69082 68050
68129
*First (top) part numbers denote crimp bar tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
**Requires Hand Actuated Power Unit Part No. 189721-2 or Foot Actuated Power Unit Part No. 189722-2.
Catalog 82020
Revised 11-02
Butt Splices
7
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Wire Size Range:
Aluminum – AWG 16 to 10
[1.25 to 5.0 mm2], CMA 2,050 to 13,100
Copper – AWG 18 to 12
[0.8 to 3 mm2], CMA 1,290 to 8,230
Wire Size Range:
Aluminum – AWG 8 to 4/0
[8.0 to 105 mm2], CMA 13,100 to 231,000
Copper – AWG 12 to 3/0
[5.0 to 85 mm2], CMA 5,180 to 190,000
Wire Size Dim. Part Numbers
[mm2]LHand* Heads for
Circular Mils Max. Tool Pneumatic Tools* Splice
Aluminum Copper 6-26 68068
16-14 18-16 .701 68041-1 — 68104 52001
[1.25] [0.8] 17.81 68140-1 189447-1 68100
2050-5180 1290-3260
12-10 14-12 .799 68042-1 — 68104,68105 52004
[5.0] [3.0] 20.29 68141-1 189444-1 68100,68101
5180-13100 3260-8230
*First (top) part numbers denote crimp bar tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
Catalog 82020
Revised 11-02
Butt Splices (Continued)
8
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Wire Size Range:
Aluminum – AWG 250 to 500 MCM
[127 to 253 mm2], CMA 231,000 to 600,000
Copper – AWG 4/0 to 400 MCM
[105 to 203 mm2], CMA 190,000 to 478,000
Wire Size Dim. Part Numbers
[mm2]LTooling for
Circular Mils Max. Power Unit 69120 Splice
Aluminum Copper Head Die Insert*
250 MCM 4/0 2.093 69082 68034 52560
[127] [105] 53.16
231000-300000 190000-231000
300 MCM 250 MCM 2.217 69082 68035 52561
[152] [127] 56.31
300000-380000 231000-300000
400 MCM 300 MCM 2.467 69082 68036 52562
[203] [152] 62.66
380000-478000 300000-380000
500 MCM 400 MCM 2.811 69082 68037 52563
[253] [203] 71.4
478000-600000 380000-478000
*Bar crimp tooling.
Important:
Butt splices will accept the same wire size at either end for aluminum-to-aluminum applica-
tions. However, for aluminum-to-copper applications, when using bar crimp tooling, the
size of the copper wire should be stepped down using one smaller wire size to compen-
sate for the differences in the physical properties between copper and aluminum. For the
correct butt splice to use, refer to the CMA ranges listed with each part number.
When two or more wires are used in either end of a butt splice, the combined cross-
section area must be within the CMA range listed.
Warning: Not approved for reconnection of residential aluminum
branch circuit wiring. (Refer to Catalog #82205.)
Catalog 82020
Revised 11-02
Parallel Splices
9
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Part Numbers
Wire Size Dim. Hand Heads for Tooling for
[mm2] L Tool* Pneumatic Tools* Power Unit 69120* Splice
Circular Mils Max. 69015 6-26 68068 Head Die Insert
16-14 .283 68041-1 — 68104 52791
[1.25] 7.19 68140-1 —189447-1 68100 — —
2050-5180
12-10 .375 68042-1 — 68104,68105 52792
[5.0] 9.53 68141-1 —189444-1 68100,68101 — —
5180-13100
8.437 68032 — 68105 68043 52745
[8.0] 11.1 —68081 1320369-1** 68101,68192-1 69099 68084
13100-20800
6.450 69999 68106 68044 52746
[14] 11.43 —68082 —68102 69099 68085
20800-33100
4.562 68045 52747
[21] 14.27 — 68038 — — 69099 68086
33100-52600
2.781 68046 52748
[35] 19.84 — — — — 69099 68130
52600-83700
1/0 .734 68047 52749
[50] 18.64 — — — — 69099 68131
83700-119500
2/0 .734 68048 52750
[70] 18.64 — — — — 69099 68132
11950-150500
3/0 .749 68049
[85] 19.02 — — — — 69099 68133 52751
150500-190000
4/0 68050
[105] .765 — — — — 69082 68129 52752
190000-231000 19.43 69099 —
318106-1
*First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
**Requires Hand Actuated Power Unit Part No. 189721-2 or Foot Actuated Power Unit Part No. 189722-2.
Important:
When two or more wires are used in a parallel splice, the combined cross-section area
must be within the CMA range listed.
Wire Size Range:
Aluminum – AWG 16 to 4/0
[1.25 to 105 mm2], CMA 2,050 to 231,000
Warning: Not approved for reconnection of residential aluminum
branch circuit wiring. (Refer to Catalog #82205.)
Catalog 82020
Revised 11-02
Tooling
10
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Manually Operated Tools
These tools are designed
for hand operation and low
volume production work or
where power is not avail-
able. They feature the
CERTI-CRIMP ratchet
device for controlled
compression crimping to
provide uniform termina-
tions consistently.
Pneumatic Tools
Designed for medium
production, these semi-
automatic power tools offer
the convenience of hand
tools plus the effortless
precision and speed of
machines. They are built for
long, rugged service and
are equipped with remov-
able crimping dies for termi-
nating a variety of AMP
products.
DYNA-CRIMP Tools
Power Unit Only (Includes
Pressure Release)
115 Volts — 69120-1
230 Volts — 69120-2
The DYNA-CRIMP Power
Unit can be equipped with
various heads and dies for
terminating COPALUM
products in wire ranges
from AWG 8 to 500 MCM
[8 to 253 mm2]. A complete
line of accessories is also
available, permitting use in
portable and stationary
applications, as well as for
multi-head crimping.
Heavy Head Hand Tool
6-26 Pneumatic Tool
(See Catalog 124208 for part
numbers and more information.)
Pneumatic Tool
Part No. 69015
Electro-Hydraulic Power Unit Power Unit
Crimping Head
Part No. 69099
Power Unit
Crimping Head
Part No. 69082
Pneumatic Tool
Part No. 68068 – As shown
Part No. 68068-3 – Foot pedal;
can be
bench
mounted
Accessories for DYNA-CRIMP Tools
Accessory Description Power Unit
Part Number Part Number
1-59907-7 7 ft. [2.13 m] Handle Control Assembly—Hose and Cord
1-59907-5 15 ft. [4.57 m] Handle Control Assembly—Hose and Cord Pressure
2-59907-1 21 ft. [6.4 m] Handle Control Assembly—Hose and Cord Release
2-59908-1 21 ft. [6.4 m] Handle Control Assembly—Cord (Less Hose) on Power
2-59907-8 28 ft. [8.53 m] Handle Control Assembly—Hose and Cord Unit Only
2-68284-1 15 ft. [4.57 m] Foot Switch Assembly (needs hose assembly) 69120-1
2-59909-3 3 ft. [0.91 m] Hose Assembly 311470-1 Quick Disconnect Coupling 69120-2
2-59909-7 7 ft. [2.13 m] Hose Assembly (Hose Half) and 68284-1
1-59909-5 15 ft. [4.57 m] Hose Assembly Foot Switch Assembly needed
2-59909-1 21 ft. [6.4 m] Hose Assembly with these hose assemblies.
59220 3-way Multi-Directional Valve For use with
2-59220-2 3-way Multi-Directional Valve (Elec. Control) Foot Switch
59221 6-way Multi-Directional Valve only
For additional tooling information call 1-800-522-6752.
Catalog 82020
Revised 11-02
Numerical Index
11
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and Dimensions are shown for Technical Support www.tycoelectronics.com
millimeters unless otherwise reference purposes only. USA: 1-800-522-6752
specified. Values in brackets Specifications subject to change. Canada: 1-905-475-6222
are metric equivalents. Mexico: 01-800-733-8926
Note: This numerical index lists all cata-
loged parts by base no. only. Complete
part nos. (with prefixes and/or suffixes)
are shown on the page(s) indicated. 50717 6
50719 5
50720 5
51826 7
51941 7
51942 7
51979 5
51982 6
51986 6
51989 6
51992 6
51995 6
52001 7
52004 7
52007 7
52010 7
52013 7
52016 7
52019 7
52558 6
52559 6
52560 8
52561 8
52562 8
Part No. Page 52563 8
52568 6
52569 6
52587 5
52590 5
52745 9
52746 9
52747 9
52748 9
52749 9
52750 9
52751 9
52752 9
52791 9
52792 9
184076 5
184079 5
184082 6
184084 6
184087 6
184090 6
184092 6
184094 6
Part No. Page
12
Answers
to your
questions are
just a phone
call or mouse
click away.
On-Line Catalog
http://catalog.tycoelectronics.com
If you prefer to find your information electronically,
check out our web site featuring a catalog containing
over 165,000 products. Customer drawings, specifica-
tions, test reports, CAD models and electrical SPICE
models, PCB layouts and panel cutouts can be down-
loaded from the web site. Cross references to hundreds
of competitors makes it even easier to find the right part
for nearly any application.
Technical Support
USA: 1-800-522-6752 • Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com/help
Our Technical Support Specialists provide information
on distributor locations, drawing/prints, application/
product specifications, PCB layouts, technical informa-
tion, plating, electrical characteristics, dimensions,
value added capabilities, and 3D modeling/simulation.
Tooling Assistance
USA: 1-800-522-6752 • Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com/help
Tooling support specialists will assist you in selecting
hand tools, machines and applicators, identify tooling
parts, and provide information about maintenance,
adjustment and repair.
Customer Service
USA: 1-800-522-6752 • Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com/help
Receive price and delivery information immediately. You
can also place new orders, change or expedite existing
orders, and request product samples and literature
through the Customer Service Department.
AMP FAX®Service
USA: 1-800-522-6752 • Canada: 1-800-245-4356
Mexico: 001-717-986-3500 (toll call to USA)
Documents available through AMP FAX include part
numbers/catalog pages, drawings, application/product
specifications, PCB layouts, and distributor information.
Order as many as 20 pages of information at a time,
with more than 100,000 drawings, specs, and more
available.
(
Support Services
82020–5M–LUG–HOP–11-02–2606-83-43-072
Printed in U.S.A. Tyco Electronics Corporation, Harrisburg, PA 17105
