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51992 Datasheet(PDF) 3 Page - Tyco Electronics
MACOM [Tyco Electronics]
51992 Datasheet(HTML) 3 Page - Tyco Electronics
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COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Dimensions are in inches and
Dimensions are shown for
millimeters unless otherwise
reference purposes only.
specified. Values in brackets
Specifications subject to change.
are metric equivalents.
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
3. Up to a maximum of 6 equal square conductors may be crimped without insulation
4. Four rectangular conductors where T
≥ 1/4W or 2 rectangular conductors where
≤ 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
], pneumatic tooling for wire sizes 16-14 through 6 AWG [1.25-2 through 15 mm
and manually operated hand tools for wire sizes 16-14 AWG [1.25-2 mm
] and 12-10 AWG
Warning: Not approved for reconnection of residential aluminum
branch circuit wiring. (Refer to Catalog #82205.)
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