i CUSTOMER HOTLINE 1 800 722-1111 1. INTRODUCTION This specification covers the application of AMP* Standard COPALUM* Terminals and Splices. These ring tongue terminals, butt spiices and parallel splices provide reliable, low-cost terminations for both aluminum and aluminum/copper wire combinations. Stranded or solid, round or rectangular conductors falling within a specified CMA (circular mil area) range may be terminated individually or in combinations in the same wire barrel. Also, the same product can be crimped to uninsulated wire using a bar crimp, or to film-insulated wire using an insulation-piercing crimp. NOTE: All dimensions are given in inches unless otherwise specified. 2. REFERENCE MATERIAL 2.1. AMP Product Specification 108-13013 covers applicable performance requirements. 2.2. The following AMP technical publications contain information on tooling operation, maintenance and inspection. IS 1310 IS 2353 Is 2397 CM 2426 IS 2456 Is 1410 IS 2366 IS 2424 IS 2432 IS 2458 CM 1950 IS 2393 IS 2425 IS 2433 IS 2465 IS 2352 IS 2394 Refer to the tables in Section 5 of this document for a complete eross-referencing of tooling to instructional materials, and of tooling to important selection information. 2.3. Customer Drawings for specific products are available from the responsible AMP engineering department. The information on Customer Drawings takes priority if there is a conflict with this specification or with any other technical documentation supplied by AMP Incorporated. 2.4. The Customer Hotline at the top of this page will connect you to an AMP Field Engineering representative. When you call for information, identify the COPALUM product line by the following numbers: REF PART NO, 50720; PRODUCT CODE 3014. The representative will then be able to direct you to peopie within AMP who are qualified to answer your questions effectively. * TRADEMARK OF AMP INCORPORATED Copyright 1968 by AMP Incorporated. All International Rights Reserved. APPLICATION AMP INCORPORATED SPECIFICATION AAIMEP | Harrisburg, Pa. 17105 ENGINEERING APPROVAL & DATE NO. William J. Vockroth 2/2/88 114-02121 PAGE TITLE STANDARD COPALIM l of 9 TERMINALS AND SPLICES LTR REVISION RECORD AMP 1250-17 (8/87)3. PRODUCT FEATURES PARALLEL RING BUTT SPLICE TERMINAL SPLICE Wire-View Openings Perforated Insert Fig. 1. Product Features 4, REQUIREMENTS 4.1. The type of crimp used must be determined by the following set of requirements: A, The bar crimp is designed to crimp bare wire only. To crimp insulated or film-insulated wire using the bar crimp, you must first strip the insulation to the appropriate length shown in the following table. Also, the bar crimp may be used to crimp solid or stranded wire in either aluminum/copper combinations or aluminum. NOTE: When bar-crimping 3 or more rectangular conductors, crimp them on edge. DO NOT crimp them across the widths of the conductors (See Figure 2). CONTACT IS CRIMPED IN THIS DIRECTION Conductors On Edge (Not Flat) Fig. 2. Crimping 3 or More Rectangular Conductors When using the bar crimp for aluminum-to-copper applications in butt splices, the copper wire should be one standard wire-gage range smaller than the aluminum wire. This compensates for their different physical properties. For example, use a number 6 aluminum wire with a number 8 copper wire. However, when two or more wires are used in either end of a butt splice, the combined wire CMA in a given wire barrel must be within the specified range listed in the table in Paragraph 4,2, 1114-02121 PAGE , [NO. 2 AMP INCORPORATED AARP | Harrisburg, Pa. 17105 AMP 1251-15CONNECTOR MARKING COPPER STRIP LENGTH AND ALUMINUM WIRE SIZE (NOMINAL) WIRE SIZE 20-18 22-18 5/16 16-14 18-14 12-10 14-10 3/8 8 10-8 6 2-6 7/16 4 6-4 19/32 2 4-2? 1/0 2-1/0 2/0 170-2/0 3/4 3/0 2/0-3/0 4/0 3/0-4/0 25/32 250 MCM 4/0-250 MCM 1-3/16 300 MCM 250-300 MCM 1-5/16 400 MCM 300-400 MCM 1-7 /16 500 MCM 400-500 MCM 1-9/16 B. The insulation-piercing crimp is designed for use with film-insulated wire only. CAUTION: Stripping the film insulation is not required, The insulation- piercing crimp is designed for use with unstripped film- insulated wire, Crimp bare wire only with the bar crimp. Otherwise, the result will not comply with UL standards and may cause a fire hazard. Use the insulation-piercing crimp only with solid copper or aluminum wire, or stranded copper wire. NOTE: DO NOT crimp stranded aluminum wire using the insulation-piercing crimp. Also, the following rules apply, as appropriate, to the crimping of wires by the insulation-piercing method (the letter references in parentheses refer to the corresponding view in Figure 3): 1. In a solid aluminum to stranded copper application, the CMA of the copper conductors should be 40% or less of the combined wire CMA being crimped. (A) 2. No more than 10 equal-size round (B) or 6 equal-size square (C) conducters may be crimped in the same wire barrel, 3. If "T" equals thickness and "W" equals width, 4 identical rectangular conductors (D)} where T 21/4 W or 2 identical rectangular conductors (E)} where T=1/4 W may be crimped in the same wire barrel. 4. Certain combinations of wire sizes and shapes may not physically fit into the recommended terminal or splice, even though the combined wire CMA suggests a proper wire barrel load. In these cases where 7 or more equal round conductors or a solid-aluminum/stranded-copper combination is used, the next larger size terminal or splice may be used with the proper PAGE NO. p> | AMP INCORPORATED 3 114-2121 AM Harrisburg, Pa. 17105 AMP 1261-15corresponding tooling. However, the combined wire CMA MUST be at least 50% of the maximum CMA rating for the larger connector. 5. For magnet wire applications, crimp no more than 10 magnet wires (without lead wire) in one wire barrel. Use a parallel splice for applications where the lead wire CMA is less than the combined magnet wire CMA and there are less than 6 conductors total. Use a butt splice when the lead wire CMA is equal to or greater than the combined magnet wire CMA, 6. When crimping different-size solid conductors, size should never vary by more than one standard wire-gage range; and perferably not by more than one-half standard wire-gage range. Look at the table in Paragraph 4.1.4. of this specification for example; when using a number 18 aluminum wire a number 2? copper wire is acceptable, but a number 20 | copper wire is preferred. Stranded 6 Equal Wire = Copper Square Barrel (40% Max) Conductors (Max) fone rerrorated 10 Equal Round uminum nser Conductors (Max (60% Min) C ) D 4 Identical E 2 Identical Rectangular Conductors Rectangular Conductors T { | NW | -T w T=kw TH kw Fig. 3. Wire Loading for Insulation Piereing Crimping PAGE No. AMp | AM? InconporaTep 4 114-02 121 Harrisburg, Pa. 17105 AMP 1251-154.2. CMA is the major determining factor in selecting a wire loading for a specific COPALUM product. The following table compares standard wire-gage ranges to the CMA ranges of copper wire and aluminum wire. ALUMINUM COPPER WIRE SIZE CMA RANGE WIRE SIZE CMA RANGE 20 - 18 810 - 2,050 22 - 20 509 - 1,290 16 - 14 2,050 - 5,180 18 - 16 1,290 - 3,260 12 10 5,180 - 13,160 14 - 12 3,260 - 8,230 8 13,100 - 20,800 12 - 10 5,180 13,100 6 20,800 - 33,100 8 13,100 - 20,800 4 33,100 - 52,600 6 20,800 - 33,100 2 52,600 - 83,700 4 33,100 - 52,600 1/0 83,700 - 119,500 2 32,600 - 83,700 2/0 119,500 - 150,500 1/0 83,700 - 119,500 3/0 150,500 - 190,000 2/0 119,500 - 150,500 4/0 190,000 - 231,000 3/0 150,500 - 190,000 250 MCM 231,000 ~- 300,000 4/0 190,000 - 231,000 300 MCM 300,000 - 380,000 250 MCM 231,000 300,000 400 MCM 380,000 - 478,000 300 MCM 300,000 - 380,000 500 MCM 478,000 600,000 400 MCM 380,000 - 478,000 4.3. In most crimping operations for electrical termination products it is important to measure a crimp height on the finished product. But with COPALUM products it is more critical for the tooling to close to the correct measurement. The proper crimping measurements and gaging procedures are given in the instructional material provided with the tooling. Refer to Section 5 of this specification for the instructional material that corresponds to the tooling you wish to use. 4.4 It ig important when working with COPALUM products to remember that aluminum wire does not hold up under bending and flexing as well as copper wire. CAUTION: DO NOT bend aluminum wires more often or more severely than is necessary to position the wires for crimping. 4.5. Before you crimp wires into a COPALUM terminal or splice, it is important to be sure that the wire range stamped on the terminal corresponds to the wire range of the tooling. Also, be sure that the total wire load is within the CMA range specified for the connector you are using. CAUTION: ALWAYS be certain that the perforated insert is in place before erimping. NEVER remove this perforated insert. Return any COPALUM Product that does not have an insert. 4.6. Several connector insulating options are available from AMP for use with COPALUM products. The need for insulation will vary with application. AMP heat shrink products provide void-free insulation, fitted to the contour of the splice or terminal by applying a controlled heat source. They are thermally PAGE NO. Ansp | AMP iIncorporaTep 5 114-02121 Harrisburg, Pa. 17105 AMP 1254-15stable and capable of withstanding continuous exposure to a wide range of temperatures. They also provide sound mechanical protection and resist moisture and chemicals. Contact AMP Engineering for proper insulating procedures. A. 5.1. A. B. 5.2, Heat shrink tubing is available in a thin-wall variety with or without sealant, medium-wall or thick-wall flame retardant with sealant, or economy thick-wall with sealant (not self-extinguishing). The shrink ratio for these products its 3 to 1 in all directions, except for the thin-wall-without-sealant variety which has a shrink ratio of 2 to l. NOTE: When using heat shrink tubing to cover an in-line wire splice, the tubing must be placed over the wire(s) before the crimping operation is performed. Insulating tapes may be used if applied liberally so that all exposed connector surfaces and bare wires are completely covered. Heat shrink self-healing (Type 1) tape is available as well as cold shrink (fusion) tape, and Master Electricians Tape, All tapes are rolled with release paper to prevent self-adhesion except for the Master Electricians Tape, AMP Flameless Heat Gun P/N 600655-1, and Baffle for Flameless Heat Gun P/N 600655-3 are available for applying heat shrink tubing and tape. Flame-exposed heat sources may also be used in applications where flammable materials are not present. However, the Flameless Heat Gun remains the recommended heat source. 5. TOOLING TYPES Tooling for AMP Standard COPALUM Terminals and Splices can be organized into three general catagories: Hand tools with integral dies are for crimping products in the smaller wire ranges. Pneumatic tooling with the appropriate crimping head or jaws will crimp small to medium range products. A Hydraulic power unit with electric controls, and a variety of crimping heads with interchangeable dies are available for crimping medium to large range products, NOTE: Tooling fer the bar crimp technique will mark the product with a square @ ; tooling for the insulation-plercing crimp technique will mark the product with a triangle & . These designations must be identified on the dies, jaws, or crimping head of the tool before you crimp the product. Pneumatic tools 69010 (IS 1410) and 69015 (I$ 1310) are equipped with interchangeable crimping heads. Pneumatic tools with base part number 68068 (CM 2426) accept pairs of crimping jaws. The heads and jaws are listed in the tables in Paragraph 5.4. of this specification. 5.3. AMP DYNA-CRIMP* Electro-Hydraulic Power Units with base number 69120 (CM 1950) will accept Crimping Heads 69099 (IS 2458) and 69082 (IS 2456). The heads accept die sets (see tables in 5.4.) PAGE NO. AM ATED 6 114-02121 ANP P INCORPOR Harrisburg, Pa. 17105 AMP 1251-155.4. The three tables below provide a complete tooling cross-reference for your convenience. The heads, jaws, and die sets are arranged with the top number representing bar crimp tooling and the bottom number representing insulation-ptercing tooling. The first time a specific tool number is listed, the instructional material for that tool is listed in parentheses following the tool number. HAND TOOLS WIRE SIZE (Aluminum) TOOLING 68040 (IS 2366) 20-18 68351-1 (IS 2465) 16-14 68041 (IS 2366) 68140-1 (IS 2465) 12-10 68042 (IS 2366) 68141-1 (IS 2465) PNEUMATIC TOOLS WIRE SIZE TOOLING (Aluminum) 69010 | 69015 68068~[ ] HEADS JAWS 50-18 68029 (IS 2424) ~ ~ 68134 (IS 2432} - 68118-1 (IS 2393) 6-14 68031 (IS 2424) 68031 68104 (1S 2394) 68093-1 (IS 2432) 68093-1 68100 (15 2393) 12-10 68030 (IS 2424) 68030 68104,68105 (IS 2394) 68080 (IS 2432) 68080 68100,68L01 (IS 2393) 3 68054 (IS 2424) 68032 (IS 2425) 68105 (IS 2394) - 6808L (IS 2433) | 68101,68192-1 (IS 2393) - 69999 (IS 2425) 68106 (1S 2394) - 68082 (IS 2433) 68102 (18 2393) i = 68038 (1S 2425) 68107 (None) PAGE NO. 114 02121 AMP INCORPORATED - AMP Harrisburg, Pa. 17105 AMP 1251-15HYDRAULIC TOOLS WIRE SLZE HEADS AND DIE INSERTS FOR 69120 (Aluminum) HEADS DIE INSERTS a 69099 68134 (IS 2432) 16-14 ~ 12-10 - 8 68043 (1S 2353) 68084 (1S 2397) 6 68044 C18 2353) 68085 (IS 2397) 4 68045 (IS 2353) 68086 (1S 2397) 2 68046 (IS 2353} 68130 (1S 2397) t/o 68047 CIS 2353) 68131 {IS 2397) 2/0 68048 (1S 2353) 68132 (IS 2397) 68049 IS 2353) 3/0 69099 68133 (IS 2397) 68050 (18 2353) 4/0 69082 68129 (None) 250 MCM 68034(LS 2353), 68012 (IS 2352) 300 MCM 68035 (1s 2353) 400 MOM 68036 (rs 2353) 500 MCM 69082 68037 (Is 2353) 5.5. AMP Pneumatic Tools with base part number 68068, and AMP DYNA-CRIMP Electro-Hydraulic Units with base part number 69120 are available with many accessories and mounting options. For a complete picture of your choices, contact your AMP representative. 6. QUALIFYING SUPPORT AMP Standard COPALUM Terminals and Splices are UL recognized. AMP INCORPORATED ANP Harrisburg, Pa. 17105 PAGE NO. 8 114-02121 4|&MP 1261-157. VISUAL AID Figure 4 shows the conditions that must exist to ensure proper application of AMP Standard COPALUM Terminals and Splices. If your product does not meet these conditions it is not acceptable for use. CAUTION: In ALL cases the perforated insert must be in place BEFORE crimping. DO NOT use any COPALUM product that does not have an insert; but return it to AMP Incorporated. No Wire Inaulation Should Enter The Wire Barrel In Any Jacket Insulation Apptication Butt Splice Crimps Should Be Oriented 180 To Each BUTT SPLICE Other To Minimize Bowing BAR RING CRIMP TERMINAL For ALL Ring Terminals And Parallel Splices, Conductors PARALLEL Must Extend Slightly SPLICE Past End of Wire Barrel Conductors Must Be Visible Through Wire-View Openings In ALL Butt Splices ALWAYS Strip Film-Insulated Wires For Use In Bar Crimp BUTT SPLICE RING INSULATION- ERM PIERCING T TNAL CRIMP ; Perforated Insert Must Be Present PARALLEL SPLICE ALL Crimps Should Be Centered On The Wire Barrels Film-Insulated Wire Need Not Be Stripped When Used With The Insulation-Piercing Crimp Fig. 4. Visual Aid PAGE NO. Ansar | Ame incorporaTeo 9 114-02121 Harrisburg, Pa. 17105 AMP 1251-75