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52004 Datasheet(PDF) 3 Page - Tyco Electronics |
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52004 Datasheet(HTML) 3 Page - Tyco Electronics |
3 / 12 page 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.) |
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