408-2432 Datasheet, PDF (2/8 Pages) Tyco Electronics – Terminal and splice crimping heads

Insulation Piercing COPALUM Terminal and Splice Crimping Heads
408-2432
2.3. Wire Selection and Loading
Solid aluminum or copper (or a combination of both)
and stranded copper conductors may be crimped in
the same wire barrel under the following conditions:
NOTE
i
Conductors must always be within CMA limits of
wire barrel.
Condition 1 – See Figure 2, Detail A.
Maximum CMA fill for copper conductor should not
exceed 40% of total CMA.
Example:Two no. 15 solid aluminum (6,400 Cir.
Mil.) plus one no. 14 stranded copper (4,000 Cir.
Mil.) equals 10,400 Cir. Mil. The one no. 14
stranded copper conductor is approximately 40%
of total CMA (10,400 Cir. Mil.) being crimped.
Condition 2 – See Figure 2, Detail B.
A maximum of 10 equal size round conductors
may be crimped without removing film insulation.
Condition 3 – See Figure 2, Detail C.
A maximum of six equal size square conductors
may be crimped without removing film insulation.
Condition 4 – See Figure 2, Detail D.
Four identical rectangular conductors, where one
conductor thickness is equal to or greater than 1/4
of the width of one conductor, may be crimped
without removing film insulation.
2 No. 15 Sol.
Aluminum = A
6,400 Cir. Mil.
Wire
Barrel
B
C
1 No. 14 Str. Copper
= 4,000 Cir. Mil.
(Not to Exceed 40%
of Total CMA) ^D
Round Copper
or Aluminum
(10 Equal Size)
W
Square Copper
or Aluminum
(6 Equal Size)
E
T
T
T = 1/4 W
F
12,000 Cir. Mil. = 59% ^{28,000 Cir. Mil.}
Loading of 20,800 Cir. Mil.
22-16
12-10
8
W
T = 1/4 W
Terminal and Splice Sizes
6
Condition 6 – See Figure 2, Detail F.
In some instances it may not be possible to fit a
particular CMA loading into the normally
recommended terminal or splice. In these cases
where seven or more equal round, or a
combination of solid aluminum and stranded
copper conductors are used, and the total CMA is
at least 50% of maximum CMA of the next larger
size terminal or splice, the larger size may be
used.
Example: Three no 14 solid conductors equal
about 12,000 Cir. Mils. This falls within the CMA
range of a 12–10 terminal or splice accepting a
maximum CMA of 13, 100 Cir. Mils. However, it
may not be possible to insert all three conductors
into the recommended terminal or splice. It is
possible to insert all three conductors into a no.
eight size terminal or splice accepting a CMA
range of 13,100–20,800 Cir. Mils. The 12,000 Cir.
Mils. amounts to 59% loading of the maximum
CMA for no. 8 size terminals or splices. Therefore,
no. 8 size terminals or splices may be used.
Condition 7 – When using a variety of solid
conductor sizes, none of the conductors should
vary more than one (1) wire gage. (Ideally not
more than 1/2 wire gage.)
2.4. Wire Preparation
CAUTION
Do NOT use stranded aluminum wire.
!
1. Select the proper terminal, or splice wire range
and crimping head combination for the wire being
used. See Figure 3.
2. Determine correct terminal or splice wire loading
by referring to Paragraph 2.3, and CMA range
listed in Figure 3.
3. Strip stranded copper wire to dimension
indicated in Figure 3.
Terminal
Butt Splice
Parallel Splices
16-14
Figure 2
Condition 5 – See Figure 2, Detail E.
Two identical rectangular conductors, where
thickness of one conductor is equal to or less than
1/4 of the width of one conductor, may be crimped
without removing film insulation.
HEAD
WIRE
RANGE
68093-1 16-14
68080 12-10
CMA
RANGE
2,050-5,180
5,180-13,100
WIRE STRIP LENGTH
(Stranded Copper
Wire Only) (mm [in.])
Max.
Min.
7.14 [.281] 8.74 [.344]
8.74 [.344] 10.31 [.406]
Figure 3
2 of 8
Tyco Electronics Corporation
Rev A