52568 datasheet, PDF - EEWORLD Datasheet

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52568: DescriptionMALE, TELECOM AND DATACOM CONNECTOR, SOLDER, PLUG; Categorysemiconductor Other integrated circuit (IC); File Size433KB，12 Pages; ManufacturerMACOM; Websitehttp://www.macom.com

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MALE, TELECOM AND DATACOM CONNECTOR, SOLDER, PLUG

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COPALUM Terminals and Splices

(For Solid & Stranded Aluminum or Copper Wire)

Catalog 82020

Revised 11-02

Product Facts

Bar Crimp Technique

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

]

Low cost, reliable termi-

nations provide stable

electrical and mechanical

performance

UL 486B Listed where indi-

cated (see page 4)

Bar crimp only

Insulation Piercing Technique

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

]

Copper body construction

Low cost, reliable termi-

nations provide stable

electrical and mechanical

performance

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

] using the bar crimp technique, and 16 to 4/0 AWG

[1.25 to 105 mm

] 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.

1992, 1993,1994 and 2002 by Tyco

Electronics Corporation.

AMP, AMP FAX, COPALUM,

CERTI-CRIMP, DYNA-CRIMP and TYCO

are trademarks.

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

≤

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

], 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

[2-6 mm

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

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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