Catalog 82020

Revised 11-02

2

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

Introduction

The Bar Crimp

© 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.

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

[1.25 to 105 mm

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