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 stripped wire applications Terminates stripped, stranded and solid (round or rectangular) aluminum and copper conductors -- individually 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 terminations provide stable electrical and mechanical performance UL 486B Listed where indi1 cated (see page 4) 1 Bar crimp only Insulation Piercing Technique Terminals and splices for aluminum-to-aluminum, copper-to-copper and aluminum-to-copper wire applications Terminates film insulated solid aluminum, film insulated solid copper, or uninsulated 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 terminations provide stable electrical and mechanical performance 1 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82020 COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Introduction Revised 11-02 The AMP family of COPALUM terminals and splices provides reliable, low cost terminations 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 overcoming the inherent problems of aluminum oxide penetration and reformation, cold flow, creep, corrosion and thermal expansion (common in aluminum-to-copper applications). Cross Section of Bar Crimp The Bar Crimp Cross Section of Insulation Piercing Crimp The bar crimp technique employs the principle of high crimp deformation to achieve electrically and mechanically reliable terminations. During crimping, the relatively soft aluminum 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 interstrand 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 portion 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. (c) 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. 2 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) The Insulation Piercing Crimp Catalog 82020 Revised 11-02 The insulation piercing crimp technique uses its specific crimp configuration and the perforated 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 conductors 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 particular 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 appropriate 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]. Technical Documents Test Reports: 110-13506 Product Specification: Warning: Not approved for reconnection of residential aluminum branch circuit wiring. (Refer to Catalog #82205.) 108-13013 Application Specification: 114-02121 3 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82020 COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Revised 11-02 Testing Data Test Results of Bar Crimp Terminations Test Results of Insulation Piercing Crimp Terminations Current Cycling: 100 cycles @ 35 amperes, AC; each cycle consisting of 15 min. "on current" and 15 min. "off current" Thermal Shock: 0.5 hr. @ +150C and 0.17 hr. in ice water per cycle; 5 amperes, DC Current Cycling: Under oil at 1375 amperes, AC Products Tested: COPALUM splices, wire size 250 MCM [127 mm2] 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 conductor (stripped). Graph curves represent individual conductor readings. Thermal Shock: 0.5 hr. @ +150C & -55C 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). Pressure Type Wire/Connector Reference Chart AMP Wire Range AWG mm2 UL Listed File E13288 AWG mm2 10-16 1.25-6 Solid or Stranded Copper or Aluminum 12-10 3-6 Solid Aluminum 14-10 2-6 Solid or Stranded Copper 8-500 MCM 8-253 Solid or Stranded Aluminum or Copper 8-500 MCM 8-253 Stranded Aluminum or Copper Connector Marking and Aluminum Wire Size AWG mm2 Copper Wire Size AWG mm2 Strip Length Nominal inch mm2 16-14 1.25-2 18-14 0.8-2 5/16 7.94 12-10 3-6 14-10 2-6 3/8 9.53 8 6 4 2 1/0 2/0 3/0 4/0 250 MCM 300 MCM 400 MCM 500 MCM 8 14 21 35 50 70 85 105 127 152 203 253 10-8 8-6 6-4 4-2 2-1/0 1/0-2/0 2/0-3/0 3/0-4/0 4/0-250 MCM 250-300 MCM 300-400 MCM 400-500 MCM 5-8 8-14 14-21 21-35 35-50 50-70 70-85 85-105 105-127 127-152 152-203 203-253 7/16 11.11 19/32 15.08 3/4 19.05 25/32 1-3/16 1-5/16 1-7/16 1-9/16 19.64 30.16 33.34 36.51 39.69 Notes: Perforated liner must be present in wire barrel. 4 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Catalog 82020 Revised 11-02 Ring Tongue Terminals Wire Size Range: Aluminum - AWG 16 to 10 [1.25 to 5.0 mm2], CMA 2,050 to 13,100 Dimensions L E Max. Max. C Min. Hand Tool* .531 13.49 1.107 28.12 .839 21.31 .564 14.33 1 68041-1 68140- .375 9.53 .375 9.53 .375 9.53 .375 9.53 .593 15.06 .593 15.06 .835 21.21 .835 21.21 .835 21.21 .835 21.21 1.173 29.79 1.173 29.79 .645 16.38 .645 16.38 .645 16.38 .645 16.38 .874 22.2 .874 22.2 .302 7.67 .302 7.67 .302 7.67 .302 7.67 .531 13.49 .531 13.49 Wire Size [mm2] Circular Mils Tongue Thickness Max. Stud Size W 16-14 [1.25] 2050-5180 .033 0.84 1/4 M6 .042 1.07 6 M3.5 8 M4 10 -- 1/4 M6 1/4 M6 5/16 M8 12-10 [5.0] 5180-13100 68042 1 68141-1 68042 1 68141-1 68042 1 68141-1 68042 1 68141-1 68042 1 68141-1 68042 1 68141-1 Part Numbers Heads for Pneumatic Tools* 6-26 68068 Terminal -- 189447-1 68100 52587-1 -- 189444-1 -- 189444-1 -- 189444-1 -- 189444-1 -- 189444-1 -- 189444-1 68105 68100, 68101 68105 68100, 68101 68105 68100, 68101 68105 68100, 68101 68105 68100, 68101 68105 68100, 68101 51979-1 51979-1 51979-2 51979-3 52590-1 52590-2 *First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. Wire Size Range: Aluminum - AWG 8 to 6 [8.0 to 14 mm2], CMA 13,100 to 33,100 Wire Size Tongue [mm2] Thickness Circular Mils Max. 8 [8.0] 13100-20800 6 [14] 20800-33100 .048 1.22 .051 1.30 Stud Size W 10 -- 1/4 M6 5/16 M8 10MM -- 10 -- 1/4 M6 5/16 M8 3/8 -- 10MM -- .500 12.7 .500 12.7 .625 15.88 .625 15.88 .500 12.7 .500 12.7 .679 17.25 .679 17.25 .679 17.25 Dimensions L E Max. Max. R Max. 1.384 35.15 1.384 35.15 1.446 36.73 1.446 36.73 1.415 35.94 1.415 35.94 1.504 38.2 1.504 38.2 1.504 38.20 .560 14.22 .560 14.22 .560 14.22 .560 14.22 .580 14.73 .580 14.73 .580 14.73 .580 14.73 .580 14.73 1.131 28.73 1.131 28.73 1.131 28.73 1.131 28.73 1.162 29.51 1.162 29.51 1.162 29.51 1.162 29.51 1.162 29.51 Part Numbers Heads for Heads & Die Inserts Pneumatic Tools* for Power Unit 69120* 6-26 69015 68068 Head Die Insert -- 68032 68105 69099 68043 1320369-1** 68081 68101, 68192-1 69099 68084 -- 68032 68105 69099 68043 1320369-1** 68081 68101, 68192-1 69099 68084 -- 68032 68105 69099 68043 1320369-1** 68081 68101, 68192-1 69099 68084 -- 68032 68105 69099 68043 1320369-1** 68081 68101, 68192-1 69099 68084 -- 69999 68106 69099 68044 -- 68082 68102 69099 68085 -- 69999 68106 69099 68044 -- 68082 68102 69099 68085 -- 69999 68106 69099 68044 -- 68082 68102 69099 68085 -- 69999 68106 69099 68044 -- 68082 68102 69099 68085 -- 69999 68106 69099 68044 -- 68082 68102 69099 68085 Terminal 150720-1 150720-1 150720-2 184076-1 150719-1 150719-1 150719-2 150719-3 184079-1 *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. 5 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82020 COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Revised 11-02 Ring Tongue Terminals (Continued) Wire Size Range: Aluminum - AWG 4 to 500 MCM [21 to 253 mm2], CMA 33,100 to 600,000 Wire Size [mm2] Circular Mils 4 [21] 33100-52600 2 [35] 52600-83700 1/0 [50] 83700-119500 2/0 [70] 119500-150500 3/0 [85] 150500-190000 4/0 [105] 190000-231000 250 MCM [127] 23100-300000 300 MCM [152] 300000-380000 400 MCM [203] 380000-478000 500 MCM [253] 478000-600000 6 Dimensions L E Max. Max. R Max. .531 13.49 .531 13.49 .531 13.49 .675 17.15 .675 17.15 .675 17.15 .675 17.15 .675 17.15 .675 17.15 .807 20.5 .807 20.49 .675 17.15 .675 17.15 .675 17.15 .807 20.5 .807 20.49 .926 23.52 .926 23.52 .926 23.52 .926 23.52 1.020 25.91 1.020 25.91 1.020 25.91 1.630 41.4 1.630 41.4 1.630 41.4 1.702 43.23 1.702 43.23 1.702 43.23 1.859 47.22 1.859 47.22 1.859 47.22 1.925 48.9 1.925 48.89 1.859 47.22 1.859 47.22 1.859 47.22 1.925 48.9 1.925 48.89 1.930 49.02 1.930 49.02 1.930 49.02 1.930 49.02 2.112 53.64 2.112 53.64 2.112 53.64 1.362 34.59 1.362 34.59 1.362 34.59 1.362 34.59 1.362 34.59 1.362 34.59 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.541 39.14 1.560 39.62 1.560 39.62 1.560 39.62 1.560 39.62 1.645 41.66 1.645 41.66 1.645 41.66 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 .625 15.88 1/2 -- 1.087 27.61 2.178 55.32 1.676 42.57 10MM -- 1.087 27.61 2.178 55.32 .130 3.30 1/2 M12 1.426 36.22 .140 3.56 1/2 M12 .158 4.01 1/2 M12 Tongue Thickness Max. .060 1.52 .060 1.52 .073 1.85 .083 2.11 .094 2.39 Stud Size W 10 -- 1/4 M6 5/16 M8 3/8 -- 1/2 -- 10MM -- 1/4 M6 5/16 M8 3/8 -- 1/2 -- 10MM -- 1/4 M6 5/16 M8 3/8 -- 1/2 -- 10MM -- 5/16 M8 3/8 -- 1/2 -- 10MM -- 7/16 -- 1/2 -- 10MM -- Heads for Pneumatic Tools* 69015 68068 68038 -- -- 68038 -- -- 68038 -- -- 68038 -- -- 68038 -- -- 68038 -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- .625 15.88 -- -- 1.676 42.57 .625 15.88 -- -- 2.602 66.09 1.987 50.47 .625 15.88 -- -- 69082 68034 1.535 38.99 2.671 67.84 2.056 52.22 .625 15.88 -- -- 69082 68035 1.738 44.15 2.790 70.87 2.175 55.25 .625 15.88 -- -- 69082 68036 .105 2.67 .182 4.62 1/2 M12 Part Numbers Heads & Die Inserts for Power Unit 69120* Head Die Insert 68045 69099 68086 68045 69099 68086 68045 69099 68086 68045 69099 68086 68045 69099 68086 68045 69099 68086 68046 69099 68130 68046 69099 68130 68046 69099 68130 68046 69099 68130 68046 69099 68130 68047 69099 68131 68047 69099 68131 68047 69099 68131 68047 69099 68131 68047 69099 68131 68048 69099 68132 68048 69099 68132 68048 69099 68132 68048 69099 68132 68049 69099 68133 68049 69099 68133 68046 69099 68130 -- 69099 318106-1 68050 69082 68129 -- 69099 318106-1 68050 69082 68129 2.004 50.9 3.187 80.95 2.447 62.15 .750 19.05 Terminal 150717-1 150717-1 150717-1 150717-3 150717-5 184082-1 151982-1 151982-1 151982-2 151982-3 184084-1 151986-1 151986-1 151986-2 151986-3 184087-1 151989-1 151989-2 151989-3 184090-1 151992-2 151992-3 184092-1 1 51995-2 184094-1 1 52559-4 1 52558-4 1 52568-4 1 -- -- 69082 68037 52569-4 *First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Catalog 82020 Revised 11-02 Butt Splices 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 [mm2] Circular Mils Aluminum Copper 16-14 18-16 [1.25] [0.8] 2050-5180 1290-3260 12-10 [5.0] 5180-13100 14-12 [3.0] 3260-8230 Part Numbers Heads for Pneumatic Tools* 6-26 68068 Dim. L Max. Hand* Tool .701 17.81 68041-1 68140-1 -- 189447-1 68104 68100 52001 .799 20.29 68042-1 68141-1 -- 189444-1 68104,68105 68100,68101 52004 Splice *First (top) part numbers denote crimp bar tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. 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 [mm2] Circular MIls Dim. L Max. Aluminum 8 [8.0] 13100-20800 Copper 12-10 [5.0] 5180-13100 6 [14] 20800-33100 6-26 Part Numbers Heads for Tooling for Pneumatic Tools* Power Unit 69120* 69015 68068 Head Die Insert* Splice 1.195 30.35 -- 1320369-1** 68032 68081 68105 68101,68192-1 69099 68043 68084 51826 8 [8.0] 13100-20800 1.340 34.04 -- 69999 68082 68106 68102 69099 68044 68085 51941 4 [21] 33100-52600 6 [14] 20800-33100 1.630 41.4 -- 68038 -- -- 69099 68045 68086 51942 2 [35] 52600-83700 4 [21] 33100-52600 1.995 50.67 -- -- -- 69099 68046 68130 52007 1/0 [50] 83700-119500 2 [35] 52600-83700 1.985 50.42 -- -- -- 69099 68047 68131 52010 2/0 [70] 119500-150500 1/0 [50] 83700-119500 1.985 50.42 -- -- -- 69099 68048 68132 52013 3/0 [85] 150500-190000 2/0 [70] 119500-150500 1.985 50.42 -- -- -- 69099 68049 68133 52016 4/0 [105] 190000-231000 3/0 [85] 150500-190000 1.985 50.42 69099 -- -- -- -- 318106-1 68050 68129 52019 69082 *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. 7 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82020 COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Revised 11-02 Butt Splices (Continued) 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 [mm2] Circular Mils Aluminum Copper 250 MCM 4/0 [127] [105] 231000-300000 190000-231000 Dim. L Max. Part Numbers Tooling for Power Unit 69120 Head Die Insert* Splice 2.093 53.16 69082 68034 52560 300 MCM [152] 300000-380000 250 MCM [127] 231000-300000 2.217 56.31 69082 68035 52561 400 MCM [203] 380000-478000 300 MCM [152] 300000-380000 2.467 62.66 69082 68036 52562 500 MCM [253] 478000-600000 400 MCM [203] 380000-478000 2.811 71.4 69082 68037 52563 *Bar crimp tooling. Important: Butt splices will accept the same wire size at either end for aluminum-to-aluminum applications. 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 compensate 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 crosssection area must be within the CMA range listed. Warning: Not approved for reconnection of residential aluminum branch circuit wiring. (Refer to Catalog #82205.) 8 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Catalog 82020 Revised 11-02 Parallel Splices Wire Size Range: Aluminum - AWG 16 to 4/0 [1.25 to 105 mm2], CMA 2,050 to 231,000 Wire Size [mm2] Circular Mils Dim. L Max. Part Numbers Hand Tool* 69015 16-14 [1.25] 2050-5180 12-10 [5.0] 5180-13100 8 [8.0] 13100-20800 6 [14] 20800-33100 4 [21] 33100-52600 2 [35] 52600-83700 1/0 [50] 83700-119500 2/0 [70] 11950-150500 3/0 [85] 150500-190000 4/0 [105] 190000-231000 Heads for Pneumatic Tools* 6-26 68068 Tooling for Power Unit 69120* Head Die Insert Splice .283 7.19 68041-1 68140-1 -- -- 189447-1 68104 68100 -- -- 52791 .375 9.53 68042-1 68141-1 -- -- 189444-1 68104,68105 68100,68101 -- -- 52792 .437 11.1 -- 68032 68081 -- 1320369-1** 68105 68101,68192-1 69099 68043 68084 52745 .450 11.43 -- 69999 68082 -- 68106 68102 69099 68044 68085 52746 .562 14.27 -- 68038 -- -- 69099 68045 68086 52747 .781 19.84 -- -- -- -- 69099 68046 68130 52748 .734 18.64 -- -- -- -- 69099 68047 68131 52749 .734 18.64 -- -- -- -- 69099 68048 68132 52750 .749 19.02 -- -- -- -- 69099 68049 68133 52751 .765 19.43 69082 -- -- -- -- 68050 68129 -- 318106-1 52752 69099 *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. Warning: Not approved for reconnection of residential aluminum branch circuit wiring. (Refer to Catalog #82205.) 9 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Catalog 82020 COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Revised 11-02 Tooling Manually Operated Tools These tools are designed for hand operation and low volume production work or where power is not available. They feature the CERTI-CRIMP ratchet device for controlled compression crimping to provide uniform terminations consistently. Pneumatic Tools Designed for medium production, these semiautomatic 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 removable crimping dies for terminating 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 Pneumatic Tool Part No. 68068 - As shown Part No. 68068-3 - Foot pedal; can be bench mounted Power Unit Crimping Head Part No. 69099 Power Unit Crimping Head Part No. 69082 Accessories for DYNA-CRIMP Tools Accessory Part Number 1-59907-7 1-59907-5 2-59907-1 2-59908-1 2-59907-8 2-68284-1 2-59909-3 2-59909-7 1-59909-5 2-59909-1 59220 2-59220-2 59221 Description Power Unit Part Number 7 ft. [2.13 m] Handle Control Assembly--Hose and Cord Pressure 15 ft. [4.57 m] Handle Control Assembly--Hose and Cord Release 21 ft. [6.4 m] Handle Control Assembly--Hose and Cord on Power 21 ft. [6.4 m] Handle Control Assembly--Cord (Less Hose) Unit Only 28 ft. [8.53 m] Handle Control Assembly--Hose and Cord 15 ft. [4.57 m] Foot Switch Assembly (needs hose assembly) 3 ft. [0.91 m] Hose Assembly 311470-1 Quick Disconnect Coupling 7 ft. [2.13 m] Hose Assembly (Hose Half) and 68284-1 15 ft. [4.57 m] Hose Assembly Foot Switch Assembly needed 21 ft. [6.4 m] Hose Assembly with these hose assemblies. 3-way Multi-Directional Valve For use with 3-way Multi-Directional Valve (Elec. Control) Foot Switch 6-way Multi-Directional Valve only 69120-1 69120-2 For additional tooling information call 1-800-522-6752. 10 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Catalog 82020 Revised 11-02 Numerical Index Note: This numerical index lists all cataloged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. Part No. 50717 50719 50720 51826 51941 51942 51979 51982 51986 51989 51992 51995 52001 52004 52007 52010 52013 52016 52019 52558 52559 52560 52561 52562 Page 6 5 5 7 7 7 5 6 6 6 6 6 7 7 7 7 7 7 7 6 6 8 8 8 Part No. 52563 52568 52569 52587 52590 52745 52746 52747 52748 52749 52750 52751 52752 52791 52792 184076 184079 184082 184084 184087 184090 184092 184094 Page 8 6 6 5 5 9 9 9 9 9 9 9 9 9 9 5 5 6 6 6 6 6 6 11 Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. Technical Support USA: 1-800-522-6752 Canada: 1-905-475-6222 Mexico: 01-800-733-8926 www.tycoelectronics.com Support Services On-Line Catalog ( Answers to your questions are just a phone call or mouse click away. 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, specifications, test reports, CAD models and electrical SPICE models, PCB layouts and panel cutouts can be downloaded 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 information, 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(R) 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. 12 82020-5M-LUG-HOP-11-02-2606-83-43-072 Printed in U.S.A. Tyco Electronics Corporation, Harrisburg, PA 17105