COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Catalog 82020
Revised 11-02
Product Facts
Bar Crimp Technique
s
Terminals and Splices for
aluminum-to-aluminum and
aluminum-to-copper strip-
ped wire applications
Terminates stripped, strand-
ed and solid (round or rec-
tangular) aluminum and
copper conductors — indi-
vidually or in combination
Eliminates messy inhibitors
Available for a broad range
of wire sizes — from 16 AWG
to 500 MCM [1.25 to 253
mm
2
]
Low cost, reliable termi-
nations provide stable
electrical and mechanical
performance
UL 486B Listed where indi-
1
cated (see page 4)
1
s
s
s
s
s
Bar crimp only
Insulation Piercing Technique
s
Terminals and splices for
aluminum-to-aluminum,
copper-to-copper and alu-
minum-to-copper wire
applications
Terminates film insulated
solid aluminum, film insu-
lated solid copper, or un-
insulated stranded copper
conductors — individually or
in combination
Stripping of film insulated
solid conductors not
required
Eliminates messy inhibitors
Available for a broad range
of wire sizes — from 16 to
4/0 AWG [1.25 to 105 mm
2
]
Copper body construction
Low cost, reliable termi-
nations provide stable
electrical and mechanical
performance
s
s
s
s
s
s
1
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Catalog 82020
Revised 11-02
Introduction
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).
Cross Section of
Bar Crimp
Cross Section of
Insulation Piercing Crimp
The Bar Crimp
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.
© 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.
2
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Catalog 82020
Revised 11-02
The Insulation
Piercing Crimp
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 mm
2
], pneumatic tooling for wire sizes 16-14 through 6 AWG [1.25-2 through 15 mm
2
]
and manually operated hand tools for wire sizes 16-14 AWG [1.25-2 mm
2
] and 12-10 AWG
[2-6 mm
2
].
Technical Documents
Test Reports:
110-13506
Product Specification:
108-13013
Warning: Not approved for reconnection of residential aluminum
branch circuit wiring. (Refer to Catalog #82205.)
Application Specification:
114-02121
3
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Testing Data
Test Results of
Bar Crimp Terminations
Test Results of Insulation Piercing
Crimp Terminations
Catalog 82020
Revised 11-02
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 mm
2
] using two 14 AWG [2 mm
2
] solid aluminum conductors
(unstripped) and one 14 AWG [2 mm
2
] stranded copper wire con-
ductor (stripped). Graph curves represent individual conductor
readings.
Current Cycling:
Under oil at 1375 amperes, AC
Products Tested:
COPALUM splices, wire size 250 MCM [
127 mm
2
]
Thermal Shock:
0.5 hr. @ +150°C & –55°C per cycle; 15 amperes,
DC
Products Tested:
COPALUM terminals wire size 8 AWG
[8 mm
2
] (terminal-to-terminal readings include two terminations
plus 4 in. [101.6 mm] of conductor length).
Pressure Type Wire/Connector Reference Chart
AMP Wire Range
AWG
mm
2
10-16
1.25-6
Solid or Stranded
Copper or Aluminum
UL Listed File E13288
AWG
mm
2
12-10
3-6
Solid Aluminum
14-10
2-6
Solid or
Stranded Copper
Connector Marking
and Aluminum Wire Size
AWG
mm
2
16-14
12-10
8
6
4
2
1/0
2/0
3/0
4/0
250 MCM
300 MCM
400 MCM
500 MCM
1.25-2
3-6
8
14
21
35
50
70
85
105
127
152
203
253
Copper Wire Size
AWG
mm
2
18-14
14-10
10-8
8-6
6-4
4-2
2-1/0
1/0-2/0
2/0-3/0
3/0-4/0
4/0-250 MCM
250-300 MCM
300-400 MCM
400-500 MCM
0.8-2
2-6
5-8
8-14
14-21
21-35
35-50
50-70
70-85
85-105
105-127
127-152
152-203
203-253
Strip Length
Nominal
inch
mm
2
5/16
3/8
7/16
19/32
7.94
9.53
11.11
15.08
3/4
19.05
8-500 MCM
8-253
Solid or Stranded
Aluminum or Copper
8-500 MCM
8-253
Stranded Aluminum
or Copper
25/32
1-3/16
1-5/16
1-7/16
1-9/16
19.64
30.16
33.34
36.51
39.69
Notes:
Perforated liner must be present in wire barrel.
4
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
COPALUM Terminals and Splices
(For Solid & Stranded Aluminum or Copper Wire)
Ring Tongue Terminals
Wire Size Range:
Aluminum – AWG 16 to 10
[1.25 to 5.0 mm
2
], CMA 2,050 to 13,100
Catalog 82020
Revised 11-02
Wire Size
[mm
2
]
Circular Mils
16-14
[1.25]
2050-5180
Tongue
Thickness
Max.
.033
0.84
Stud
Size
W
Dimensions
L
E
Max.
Max.
1.107
28.12
.835
21.21
.835
21.21
.835
21.21
.835
21.21
1.173
29.79
1.173
29.79
.839
21.31
.645
16.38
.645
16.38
.645
16.38
.645
16.38
.874
22.2
.874
22.2
C
Min.
.564
14.33
.302
7.67
.302
7.67
.302
7.67
.302
7.67
.531
13.49
.531
13.49
Hand
Tool*
1
68041-
1
68140-
68042
1
-
68141-1
68042
1
-
68141-1
68042
1
-
68141-1
68042
1
-
68141-1
68042
1
-
68141-1
68042
1
-
68141-1
Part Numbers
Heads for
Pneumatic Tools*
6-26
68068
—
189447-1
—
189444-1
—
189444-1
—
189444-1
—
189444-1
—
189444-1
—
189444-1
68100
68105
68100, 68101
68105
68100, 68101
68105
68100, 68101
68105
68100, 68101
68105
68100, 68101
68105
68100, 68101
Terminal
1/4
M6
6
M3.5
8
M4
10
—
1/4
M6
1/4
M6
5/16
M8
.531
13.49
.375
9.53
.375
9.53
.375
9.53
.375
9.53
.593
15.06
.593
15.06
52587-1
51979-1
51979-1
51979-2
51979-3
52590-1
52590-2
12-10
[5.0]
5180-13100
.042
1.07
*First (top) part numbers denote bar crimp tooling. Second (bottom) part numbers denote insulation piercing crimp tooling.
Wire Size Range:
Aluminum – AWG 8 to 6
[8.0 to 14 mm
2
], CMA 13,100 to 33,100
Wire Size
Tongue
[mm
2
]
Thickness
Circular Mils
Max.
Stud
Size
10
—
1/4
M6
5/16
M8
10MM
—
10
—
1/4
M6
5/16
M8
3/8
—
10MM
—
W
.500
12.7
.500
12.7
.625
15.88
.625
15.88
.500
12.7
.500
12.7
.679
17.25
.679
17.25
.679
17.25
Dimensions
L
E
Max.
Max.
1.384
35.15
1.384
35.15
1.446
36.73
1.446
36.73
1.415
35.94
1.415
35.94
1.504
38.2
1.504
38.2
1.504
38.20
1.131
28.73
1.131
28.73
1.131
28.73
1.131
28.73
1.162
29.51
1.162
29.51
1.162
29.51
1.162
29.51
1.162
29.51
R
Max.
.560
14.22
.560
14.22
.560
14.22
.560
14.22
.580
14.73
.580
14.73
.580
14.73
.580
14.73
.580
14.73
8
[8.0]
13100-20800
.048
1.22
6
[14]
20800-33100
.051
1.30
Part Numbers
Heads for
Heads & Die Inserts
Pneumatic Tools*
for Power Unit 69120*
6-26
69015
68068
Head
Die Insert
—
68032
68105
69099
68043
1320369-1** 68081
68101, 68192-1
69099
68084
—
68032
68105
69099
68043
1320369-1** 68081
68101, 68192-1
69099
68084
—
68032
68105
69099
68043
1320369-1** 68081
68101, 68192-1
69099
68084
—
68032
68105
69099
68043
1320369-1** 68081
68101, 68192-1
69099
68084
—
69999
68106
69099
68044
—
68082
68102
69099
68085
—
69999
68106
69099
68044
—
68082
68102
69099
68085
—
69999
68106
69099
68044
—
68082
68102
69099
68085
—
69999
68106
69099
68044
—
68082
68102
69099
68085
—
69999
68106
69099
68044
—
68082
68102
69099
68085
Terminal
1
50720-1
150720-1
150720-2
184076-1
1
50719-1
150719-1
150719-2
150719-3
184079-1
*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.
5
Dimensions are in inches and
millimeters unless otherwise
specified. Values in brackets
are metric equivalents.
Dimensions are shown for
reference purposes only.
Specifications subject to change.
Technical Support
USA: 1-800-522-6752
Canada: 1-905-475-6222
Mexico: 01-800-733-8926
www.tycoelectronics.com
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