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51992 Datasheet(PDF) 2 Page - Tyco Electronics

Part No. 51992
Description  COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire)
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Maker  MACOM [Tyco Electronics]
Homepage  http://www.macom.com
Logo MACOM - Tyco Electronics

51992 Datasheet(HTML) 2 Page - Tyco Electronics

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Catalog 82020
Revised 11-02
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and
Dimensions are shown for
Technical Support
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 Bar Crimp
© Copyright 1972, 1973, 1974, 1984,
1992, 1993,1994 and 2002 by Tyco
Electronics Corporation.
All Rights Reserved.
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 mm
2] using the bar crimp technique, and 16 to 4/0 AWG
[1.25 to 105 mm
2] 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

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