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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 COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Catalog 82020 Revised 11-02 Product Facts Bar Crimp Technique n Terminals and Splices for aluminum-to-aluminum and aluminum-to-copper strip- ped wire applications n Terminates stripped, strand- ed and solid (round or rec- tangular) aluminum and copper conductors — indi- vidually or in combination n Eliminates messy inhibitors n Available for a broad range of wire sizes — from 16 AWG to 500 MCM [1.25 to 253 mm2] n Low cost, reliable termi- nations provide stable electrical and mechanical performance n UL 486B Listed where indi- cated (see page 4) 1

1 Bar crimp only

Insulation Piercing Technique n Terminals and splices for aluminum-to-aluminum, copper-to-copper and alu- minum-to-copper wire

applications

n Terminates film insulated solid aluminum, film insu- lated solid copper, or un- insulated stranded copper conductors — individually or in combination n Stripping of film insulated solid conductors not required n Eliminates messy inhibitors n Available for a broad range of wire sizes — from 16 to 4/0 AWG [1.25 to 105 mm2] n Copper body construction n Low cost, reliable termi- nations provide stable electrical and mechanical performance

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 mm2] using the bar crimp technique, and 16 to 4/0 AWG [1.25 to 105 mm2] 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

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.)

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 Test Results of Insulation Piercing Crimp Terminations Current Cycling: Under oil at 1375 amperes, AC Products Tested: COPALUM splices, wire size 250 MCM [ 127 mm2] Pressure Type Wire/Connector Reference Chart AMP Wire Range UL Listed File E13288 Connector Marking Copper Wire Size Strip Length and Aluminum Wire Size Nominal AWG mm 2 AWG mm 2 AWG mm 2 AWG mm 2 inch mm 2 12-10 3-6 10-16 1.25-6 Solid Aluminum 16-14 1.25-2 18-14 0.8-2 5/16 7.94 Solid or Stranded 14-10 2-6 Copper or Aluminum Solid or 12-10 3-6 14-10 2-6 3/8 9.53Stranded Copper 8 8 10-8 5-8 6 14 8-6 8-14 7/16 11.11 4 21 6-4 14-21 19/32 15.08 2 35 4-2 21-35 1/0 50 2-1/0 35-50 8-500 MCM 8-253 8-500 MCM 8-253 2/0 70 1/0-2/0 50-70 3/4 19.05 Solid or Stranded Stranded Aluminum 3/0 85 2/0-3/0 70-85 Aluminum or Copper or Copper 4/0 105 3/0-4/0 85-105 25/32 19.64 250 MCM 127 4/0-250 MCM 105-127 1-3/16 30.16 300 MCM 152 250-300 MCM 127-152 1-5/16 33.34 400 MCM 203 300-400 MCM 152-203 1-7/16 36.51 500 MCM 253 400-500 MCM 203-253 1-9/16 39.69 Notes: Perforated liner must be present in wire barrel. Thermal Shock:0.5 hr. @ +150°C & –55°C per cycle; 15 amperes, DC Products Tested:COPALUM terminals wire size 8 AWG [8 mm2] (terminal-to-terminal readings include two terminations plus 4 in. [101.6 mm] of conductor length). Current Cycling:100 cycles @ 35 amperes, AC; each cycle con- sisting of 15 min. “on current” and 15 min. “off current” Thermal Shock:0.5 hr. @ +150°C and 0.17 hr. in ice water per cycle; 5 amperes, DC Products Tested:COPALUM parallel splices, wire size 8 AWG [8 mm2] using two 14 AWG [2 mm2] solid aluminum conductors (unstripped) and one 14 AWG [2 mm2] stranded copper wire con- ductor (stripped). Graph curves represent individual conductor readings. Test Results of Bar Crimp Terminations

Tongue Dimensions Part Numbers Wire Size Thickness Stud Heads for[mm 2] Max. Size W L E C Hand Pneumatic Tools* TerminalCircular Mils Max. Max. Min. Tool* 6-26 68068 2050-5180 6 .375 .835 .645 .302 68042-1 — 68105 51979-1 *First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. Catalog 82020 Revised 11-02 Ring Tongue Terminals 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 Tongue Dimensions Part Numbers Wire Size Thickness Stud Heads for Heads & Die Inserts[mm 2] Max. Size W L E R Pneumatic Tools* for Power Unit 69120* TerminalCircular Mils Max. Max. Max. 6-26 69015 68068 Head Die Insert 8 1/4 .500 1.384 1.131 .560 — 68032 68105 69099 68043 150720-1 *First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. **Requires Hand Actuated Power Unit Part No. 189721-2 or Foot Actuated Power Unit Part No. 189722-2. Wire Size Range: Aluminum – AWG 16 to 10 [1.25 to 5.0 mm2], CMA 2,050 to 13,100 Wire Size Range: Aluminum – AWG 8 to 6 [8.0 to 14 mm2], CMA 13,100 to 33,100

Ring Tongue Terminals (Continued) 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 Wire Size Range: Aluminum – AWG 4 to 500 MCM [21 to 253 mm2], CMA 33,100 to 600,000 Tongue Dimensions Part Numbers Wire Size Thickness Stud Heads for Heads & Die Inserts[mm 2] Max. Size W L E R Pneumatic Tools* for Power Unit 69120* TerminalCircular Mils Max. Max. Max. 69015 68068 Head Die Insert 5/16 .675 1.859 1.541 .625 68046 151982-1 2 M8 17.15 47.22 39.14 15.88 — — 69099 68130 5/16 .675 1.859 1.541 .625 68047 151986-1 1/0 M8 17.15 47.22 39.14 15.88 — — 69099 68131 2/0 3/8 .926 1.930 1.560 .625 68048 151989-2 7/16 1.020 2.112 1.645 .625 68049 151992-2 — 25.91 53.64 41.66 15.88 — — 69099 68133 1/2 1.087 2.178 1.676 .625 69099 318106-1 151995-2 — 27.61 55.32 42.57 15.88 — — 69082 68050 [105] .105 68129 190000-231000 2.67 69099 — 69082 68050 68129 23100-300000 478000-600000 *First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.

Dim. Part Numbers [mm 2] L Heads for Tooling for Circular MIls Max. Pneumatic Tools* Power Unit 69120* Splice Aluminum Copper 6-26 69015 68068 Head Die Insert* 8 12-10 1.195 — 68032 68105 69099 68043 51826[8.0] [5.0] 30.35 1320369-1** 68081 68101,68192-1 6808413100-20800 5180-13100 6 8 1.340 69999 68106 69099 68044 51941[14] [8.0] 34.04 — 68082 68102 6808520800-33100 13100-20800 4 6 1.630 69099 68045 51942[21] [14] 41.4 — 68038 — 6808633100-52600 20800-33100 — 2 4 1.995 69099 68046 52007[35] [21] 50.67 — — — 6813052600-83700 33100-52600 1/0 2 1.985 69099 68047 52010[50] [35] 50.42 — — — 6813183700-119500 52600-83700 2/0 1/0 1.985 69099 68048 52013[70] [50] 50.42 — — — 68132119500-150500 83700-119500 3/0 2/0 1.985 69099 68049 52016[85] [70] 50.42 — — — 68133150500-190000 119500-150500 4/0 3/0 — 69099 318106-1 52019 190000-231000 150500-190000 50.42 69082 68050 68129 *First (top) part numbers denote crimp bar tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. **Requires Hand Actuated Power Unit Part No. 189721-2 or Foot Actuated Power Unit Part No. 189722-2. Catalog 82020 Revised 11-02 Butt Splices 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 Wire Size Range: Aluminum – AWG 16 to 10 [1.25 to 5.0 mm2], CMA 2,050 to 13,100 Copper – AWG 18 to 12 [0.8 to 3 mm2], CMA 1,290 to 8,230 Wire Size Range: Aluminum – AWG 8 to 4/0 [8.0 to 105 mm2], CMA 13,100 to 231,000 Copper – AWG 12 to 3/0 [5.0 to 85 mm2], CMA 5,180 to 190,000 Wire Size Dim. Part Numbers [mm 2] L Hand* Heads for Circular Mils Max. Tool Pneumatic Tools* Splice Aluminum Copper 6-26 68068 16-14 18-16 .701 68041-1 — 68104 52001[1.25] [0.8] 17.81 68140-1 189447-1 681002050-5180 1290-3260 12-10 14-12 .799 68042-1 — 68104,68105 52004[5.0] [3.0] 20.29 68141-1 189444-1 68100,681015180-13100 3260-8230 *First (top) part numbers denote crimp bar tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.

Butt Splices (Continued) 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 Wire Size Range: Aluminum – AWG 250 to 500 MCM [127 to 253 mm2], CMA 231,000 to 600,000 Copper – AWG 4/0 to 400 MCM [105 to 203 mm2], CMA 190,000 to 478,000 Wire Size Dim. Part Numbers [mm 2] L Tooling for Circular Mils Max. Power Unit 69120 Splice Aluminum Copper Head Die Insert* 250 MCM 4/0 2.093 69082 68034 52560[127] [105] 53.16231000-300000 190000-231000 300 MCM 250 MCM 2.217 69082 68035 52561[152] [127] 56.31300000-380000 231000-300000 400 MCM 300 MCM 2.467 69082 68036 52562[203] [152] 62.66380000-478000 300000-380000 500 MCM 400 MCM 2.811 69082 68037 52563[253] [203] 71.4478000-600000 380000-478000 *Bar crimp tooling. Important: Butt splices will accept the same wire size at either end for aluminum-to-aluminum applica- tions. However, for aluminum-to-copper applications, when using bar crimp tooling, the size of the copper wire should be stepped down using one smaller wire size to compen- sate for the differences in the physical properties between copper and aluminum. For the correct butt splice to use, refer to the CMA ranges listed with each part number. When two or more wires are used in either end of a butt splice, the combined cross- section area must be within the CMA range listed. Warning: Not approved for reconnection of residential aluminum branch circuit wiring. (Refer to Catalog #82205.)

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 Part Numbers Wire Size Dim. Hand Heads for Tooling for[mm 2] L Tool* Pneumatic Tools* Power Unit 69120* SpliceCircular Mils Max. 69015 6-26 68068 Head Die Insert 16-14 .283 68041-1 — 68104 52791[1.25] 7.19 68140-1 — 189447-1 68100 — — 2050-5180 12-10 .375 68042-1 — 68104,68105 52792[5.0] 9.53 68141-1 — 189444-1 68100,68101 — — 5180-13100 8 .437 68032 — 68105 68043 52745[8.0] 11.1 — 68081 1320369-1** 68101,68192-1 69099 6808413100-20800 6 .450 69999 68106 68044 52746[14] 11.43 — 68082 — 68102 69099 6808520800-33100 4 .562 68045 52747[21] 14.27 — 68038 — — 69099 6808633100-52600 2 .781 68046 52748[35] 19.84 — — — — 69099 6813052600-83700 1/0 .734 68047 52749[50] 18.64 — — — — 69099 6813183700-119500 2/0 .734 68048 52750[70] 18.64 — — — — 69099 6813211950-150500 3/0 .749 68049[85] 19.02 — — — — 69099 68133 52751 150500-190000 4/0 68050 [105] .765 — — — — 69082 68129 52752 190000-231000 19.43 69099 — 318106-1 *First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling. **Requires Hand Actuated Power Unit Part No. 189721-2 or Foot Actuated Power Unit Part No. 189722-2. Important: When two or more wires are used in a parallel splice, the combined cross-section area must be within the CMA range listed. Wire Size Range: Aluminum – AWG 16 to 4/0 [1.25 to 105 mm2], CMA 2,050 to 231,000 Warning: Not approved for reconnection of residential aluminum branch circuit wiring. (Refer to Catalog #82205.)

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 Manually Operated Tools These tools are designed for hand operation and low volume production work or where power is not avail- able. They feature the CERTI-CRIMP ratchet device for controlled compression crimping to provide uniform termina- tions consistently. Pneumatic Tools Designed for medium production, these semi- automatic power tools offer the convenience of hand tools plus the effortless precision and speed of machines. They are built for long, rugged service and are equipped with remov- able crimping dies for termi- nating a variety of AMP products. DYNA-CRIMP Tools Power Unit Only (Includes Pressure Release)

115 Volts — 69120-1

230 Volts — 69120-2

various heads and dies for terminating COPALUM products in wire ranges from AWG 8 to 500 MCM [8 to 253 mm2]. A complete line of accessories is also available, permitting use in portable and stationary applications, as well as for multi-head crimping. Heavy Head Hand Tool 6-26 Pneumatic Tool (See Catalog 124208 for part numbers and more information.) Pneumatic Tool Part No. 69015 Electro-Hydraulic Power Unit Power Unit Crimping Head Part No. 69099 Power Unit Crimping Head Part No. 69082 Pneumatic Tool Part No. 68068 – As shown Part No. 68068-3 – Foot pedal; can be bench mounted Accessories for DYNA-CRIMP Tools Accessory Description Power Unit Part Number Part Number 1-59907-7 7 ft.[2.13 m] Handle Control Assembly—Hose and Cord 1-59907-5 15 ft.[4.57 m] Handle Control Assembly—Hose and Cord Pressure 2-59907-1 21 ft.[6.4 m] Handle Control Assembly—Hose and Cord Release 2-59908-1 21 ft.[6.4 m] Handle Control Assembly—Cord (Less Hose)on Power 2-59907-8 28 ft.[8.53 m] Handle Control Assembly—Hose and Cord Unit Only 2-68284-1 15 ft.[4.57 m] Foot Switch Assembly (needs hose assembly) 69120-1 2-59909-3 3 ft.[0.91 m] Hose Assembly 311470-1 Quick Disconnect Coupling 69120-2 2-59909-7 7 ft.[2.13 m] Hose Assembly (Hose Half) and 68284-1 1-59909-5 15 ft.[4.57 m] Hose Assembly Foot Switch Assembly needed 2-59909-1 21 ft.[6.4 m] Hose Assembly with these hose assemblies. 59220 3-way Multi-Directional Valve For use with 2-59220-2 3-way Multi-Directional Valve (Elec. Control) Foot Switch 59221 6-way Multi-Directional Valve only For additional tooling information call 1-800-522-6752.

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 Note: This numerical index lists all cata- loged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. 50717 6 50719 5 50720 5 51826 7 51941 7 51942 7 51979 5 51982 6 51986 6 51989 6 51992 6 51995 6 52001 7 52004 7 52007 7 52010 7 52013 7 52016 7 52019 7 52558 6 52559 6 52560 8 52561 8 52562 8 Part No. Page 52563 8 52568 6 52569 6 52587 5 52590 5 52745 9 52746 9 52747 9 52748 9 52749 9 52750 9 52751 9 52752 9 52791 9 52792 9 184076 5 184079 5 184082 6 184084 6 184087 6 184090 6 184092 6 184094 6 Part No. Page

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