AMPOWER Terminals and Splices Catalog Revised 05-95

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atalog 805 Product Facts Designed for large cables and leads Ideally suited for power generation and distribution Accepts a wide range of stranded copper wires (6 AWG to 000 MM [3-507 mm ] for

Laboratories, Inc. File No. E388, Spec. 486 ertified by the anadian Standards Association File No.

requirements. AMPOWER terminals and splices are ideally suited for power generation and distribution.

1 atalog 805 Product Facts Designed for large cables and leads Ideally suited for power generation and distribution Accepts a wide range of stranded copper wires (6 AWG to 000 MM [3-507 mm ] for terminals and up to 500 MM [760 mm ] for splices) Available in a variety of terminal and splice styles High-quality, seamless tubular copper for maximum conductivity Listed by Underwriters Laboratories, Inc. File No. E388, Spec. 486 ertified by the anadian Standards Association File No. LR789 Technical Documents: Instruction Sheets The AMPOWER product line is available in a variety of terminal and splice styles to suit your design requirements. AMPOWER terminals and splices are ideally suited for power generation and distribution. This makes electrical equipment subject to continuous operation, such as generators, motors and welders, a perfect application for AMPOWER products. In addition, other applications include interconnections of power supplies to computers and peripheral equipment. 00 by Tyco Electronics orporation. All rights reserved. AMP, AMP FAX, AMPOWER, DYNA-RIMP, and TYO are trademarks. anada:

atalog 805 Table of ontents Product Facts, Technical Documents... Performance Requirements...3 Features....4 Terminals...5-9 Splices....9- Special Terminals.... Tooling...3-4 Index....5 Support Services.

The application technique is totally mechanical and therefore completely controllable. For this reason it is also uniform from first to last crimp.

2 atalog 805 Table of ontents Product Facts, Technical Documents... Performance Requirements...3 Features....4 Terminals Splices Special Terminals.... Tooling Index....5 Support Services....6 rimp Method Specified Packaging Stud Size Dimensions Our compression crimping method of terminating electrical wire is an exact science. The application technique is totally mechanical and therefore completely controllable. For this reason it is also uniform from first to last crimp. Variables common to other methods such as melting temperature, flux composition, entrapped gases, heat deformation of conductors, oxidation and the like are eliminated. The termination resulting from this method offers excellent tensile strength and high conductivity. AMPOWER terminals and splices are made of high quality seamless tubular copper for excellent conductivity. Our special tin plating process inhibits corrosion, and provides trouble-free service. A special die stamping process converts the copper tube into a double thickness rectangular tongue with a short strong transfer section. These factors combine with the formulated AMPOWER terminal crimp to produce excellent conductivity and excellent strength. efore rimping Wire Size After rimping No. of Terminals Per Package 6 and 4 AWG 00 AWG and /0 thru 50 4/0 AWG MM 5 Stud Stud Stud Hole Size Dia. Dia / M / M / / M / M / / M / / Use as an aid for the selection of proper terminal size. anada:

3 atalog 805 Performance Requirements 3 anada:

atalog 805 Features. Versatility Stranded wires, crimped with the DYNA-RIMP tool, become almost a homogeneous mass with the AMPOWER terminal or splice barrel.

omplementing this versatility is the stud hole style available with AMPOWER terminals.

. Strength AMPOWER terminals have formidable strength and resistance to vibration suitable for their intended use.

In addition, great tensile strength is imparted to the AMPOWER terminals and splices by means of AMP s formulated crimp-tensile strength approaches the strength of

This is a result of the tool and terminal team, the elimination of clutter found in other methods, plus the speed and ease of application.

4 Terminals With Two Stud Holes See pages 5-9 Standard Terminals With One Stud Hole See pages 5-9 Standard Terminals Without Stud Hole See pages 5-9 Long arrel

barrel into an almost homogeneous unit. As a result, conductivity is maximized and tensile strength approaches that of the wire.

Tests of temperature rise above ambient also confirm the excellent performance of AMPOWER terminals and splices. 5.

4 atalog 805 Features. Versatility Stranded wires, crimped with the DYNA-RIMP tool, become almost a homogeneous mass with the AMPOWER terminal or splice barrel. Long barrel terminals and splices are offered for applications where space limitations and accessibility make it difficult to locate the proper crimp area. omplementing this versatility is the stud hole style available with AMPOWER terminals. They are supplied with one, two or without stud holes for special requirements, or they can be ordered with extra long tongues at a slightly higher cost.. Strength AMPOWER terminals have formidable strength and resistance to vibration suitable for their intended use. This strength comes from the double-thick tongue and short transfer section of the barrel, and is achieved without sacrificing any current carrying capacity. In addition, great tensile strength is imparted to the AMPOWER terminals and splices by means of AMP s formulated crimp-tensile strength approaches the strength of the conductors. 3. Economy An important part of all AMP products is low installed cost. This is a result of the tool and terminal team, the elimination of clutter found in other methods, plus the speed and ease of application. And AMP s matching tooling creates the correct crimp. As a result, you save money every time an AMPOWER product is installed. 4 Terminals With Two Stud Holes See pages 5-9 Standard Terminals With One Stud Hole See pages 5-9 Standard Terminals Without Stud Hole See pages 5-9 Long arrel Terminal With Stud Hole See pages 5-9 Long arrel Terminal Without Stud Hole See pages 5-9 Parallel Splice See page utt Splice See page 0 Long arrel utt Splice See page 8 4. onductivity, orrosion Resistance and Temperature Rise The center of the AMP termination method is the exactly controlled crimp that forms the terminal or splice barrel into an almost homogeneous unit. As a result, conductivity is maximized and tensile strength approaches that of the wire. Proper compression crimping brings the terminal into intimate contact with the conductor, producing excellent resistance to corrosion. Tests of temperature rise above ambient also confirm the excellent performance of AMPOWER terminals and splices. 5. Positive Inspection Standard AMPOWER terminals and splices are supplied with inspection slots in the barrel, allowing the tool operator or inspector to determine at a glance whether the conductors have been fully and properly inserted into the barrel. This can be done either before or after crimping. Wire stops prevent over insertion of conductors, and bell mouth construction makes it easy to insert conductors into the barrel. 6. road Wire Size Range overing wire sizes from 6 AWG to 000 MM [3 to 507 mm ] for terminals and up to 500 [760 mm ] for splices. AMPOWER terminals and splices provide reliability and low cost installation for power equipment using large cable sizes. Note: See page for Special Terminals. 4 anada:

5 atalog 805 Terminals ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Wire arrel Tongue Dimensions I.D. Thickness Stud Size Range Style Size L H K F W Min. Max. Max. Max. Min. Min. Max. A / AWG 0, M , mm 5/ M M A / M / M AWG 33,00-5, / mm M M A / M / M / M AWG 5, , mm M A A A G / M / M / /0 AWG 83, M , mm M I 7/ / M /.4.87 M / M Per NEMA specification. Terminals for wire sizes 6 AWG and 4 AWG are manufactured from annealed copper per ASTM anada:

6 atalog 805 Terminals (ontinued) ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Wire arrel Tongue Dimensions I.D. Thickness Stud Size Range Style Size L H K F W Min. Max. Max. Max. Min. Min. Max. /4..47 M /6..47 M / M ** 3540-** ** 5/ M ** ** /0 AWG 9, , / ** mm M M A ** H G I / M / M / M /0 AWG 50,500- A , mm M G I A 5/ M / M / M ** 3540-** 354-** ** 3550-** ** ** ** 3554-** 3556-** 5368-** 3680-** ** 3560-** ** ** / M ** 4/0 AWG 90, , ** mm M A ** ** No sight hole. Per NEMA specification. A G I / M ** 3564-** 3784-** / M ** 6 anada:

7 atalog 805 Terminals (ontinued) ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Wire arrel Tongue Dimensions I.D. Thickness Stud Size Range Style Size L H K F W Min. Max. Max. Max. Min. Min. Max. 50 MM mm MM MM mm MM * leaned but not plated. ** No sight hole. Per NEMA Specifications. A A A A G A A G I 5/6.58 M ** ** /.58 M ** 5/ ** ** ** ** ** ** ** / M ** 5/ M ** 5/6.69 M ** ** *** /.69 M ** /.69 M ** ** 5/ ** ** ** / M ** ** ** ** ** / M anada:

8 atalog 805 Terminals (ontinued) ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Wire arrel Tongue Dimensions I.D. Thickness Stud Size Range Style Size L H K F W Min. Max. Max. Max. Min. Min. Max. A ** / M ** A *-* ** / M ** 350 MM / mm MM M ** A ** ** ** / M ** I / M ** A ** / M ** / M ** 5/8 M ** 400 MM A mm MM *** ** ** G ** H 5/8 M ** ** / M ** 5/8 M ** A *** A ** MM 53mm MM A ** / M ** ** G ** I / M ** **leaned but not plated. **No sight hole. Per NEMA specification. 8 anada:

9 atalog 805 Terminals (ontinued) and Splices ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Note: Refer to art on facing page. Wire Size Wire Range arrel Tongue Dimensions I.D. Thickness Stud Style Size L H K F W Min. Max. Max. Max. Min. Min. Max. F / M ** D F F ** G ** MM MM F mm ** / M ** / M ** 700 E / ** M MM 355mm MM I / M ** E F / ** 800 E 5/ ** M MM MM mm D ** / M * 000 MM / * MM F 507mm M ** leaned but not plated. ** No sight hole. Two crimps necessary. Splices Long arrel utt Splice Wire Size Range: /0 AWG to 500 MM [50 to 53 mm ] ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Wire Size Range /0 AWG 83,700-9,500 M 4/0 AWG 90-3 MM 50 MM 3-75 MM 350 MM MM 400 MM MM 500 MM MM arrel Dimensions I.D. T L Min. Max anada:

10 atalog 805 Splices (ontinued) utt Splice Wire Size Range: AWG to 500 MM [34 to 760 mm ] ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Size Wire Range AWG 5,600-83,700 M /0 AWG 83,700-9,500 M /0 AWG 9,500-50,500 M 3/0 AWG 50,500-90,000 M 3/0 AWG 50,500-90,000 M 4/0 AWG 90-3 MM 4/0 AWG 90-3 MM 50 MM 3-75 MM 300 MM MM 300 MM MM 350 MM MM 400 MM MM 500 MM MM 500 MM MM 600 MM MM 600 MM MM 700 MM MM 800 MM MM 800 MM MM 900 MM MM 000 MM MM -4* 000 MM MM 50 MM MM 500 MM MM *leaned but not plated. Two crimps necessary on each end. arrel Dimensions I.D. T L Min. Max * * * * * * * * * * * * * * * * * anada:

11 atalog 805 Splices (ontinued) Parallel Splice Wire Size Range: AWG to 000 MM [34 to 507 mm ] ase Material: Annealed opper (ASTM -88) Electrodeposited Tin Plate (MIL-T-077) Wire Size Wire Range AWG 5,600-83,700 M AWG 5,600-83,700 M /0 AWG 83,700-9,500 M /0 AWG 9,500-90,000 M /0 AWG 9,500-90,000 M 3/0 AWG 50,500-90,000 M 4/0 AWG 90-3 MM 4/0 AWG 90-3 MM 50 MM 3-75 MM 300 MM MM 300 MM MM 350 MM MM 400 MM MM 500 MM MM 500 MM MM 600 MM MM 700 MM MM 800 MM MM 800 MM MM 900 MM MM 900 MM MM 000 MM MM 000 MM MM *leaned but not plated. Two crimps necessary. arrel Dimensions I.D. T L Min. Max * * * * * * * * anada:

12 atalog 805 Special Terminals enterline -Hole 90 ent Terminals Wire Size Range: AWG to 350 MM [34 to 375 mm ] 90 ent Wire Wire Stud Size Range Size Slotted Stud Hole Heavy Duty 4-Hole arrel Tongue Dimensions I.D. Thickness L W F H Min. Max. Min. Max. Min. Max. 3/ () / AWG 5,600 M ,700 mm M / M /0 AWG 83,700-9,500 5/ M M /0 AWG 90-3 MM ** Two Stud Holes 353-** 35-** 5583-** 5587-** 3530** ** Slotted Stud Hole Wire Size Range: 400 to 500 MM [03 to 53 mm ] Heavy Duty 4-Hole Wire Size Range: 350 to 600 MM [77mm to 304mm ] enter -Hole Terminals Wire Size Range: 4/0 AWG to 600 MM [00 mm to 304 mm ] Wire Wire Stud Size Range Size arrel Tongue Dimensions I.D. Thickness L H K W Min. Max. Max. Max. Min. Max MM MM MM MM Wire Wire Stud Size Range Size arrel Tongue Dimensions I.D. Thickness L H K W Min. Max. Max. Max. Min. Max / MM MM M / MM MM M / MM MM M Two crimps necessary. Dimensions Wire Wire Stud arrel Tongue Size Range Size I.D. Thickness L H K W Min. Max. Max. Max. Min. Max. 4/0 AWG 90-3 MM 5/6 M MM MM MM MM MM MM Two crimps necessary anada:

13 atalog 805 Tooling DYNA-RIMP Tool Heads and Dies Hydraulic Hand Tool No (See chart for die numbers) Head No. Instruction Sheet Wire Size Dies 6 AWG AWG AWG /0 AWG /0 AWG /0 AWG /0 AWG MM MM MM MM MM MM MM MM HD MM MM MM MM MM MM MM MM MM MM MM AWG /0 AWG /0 AWG (Hand Tool) /0 AWG /0 AWG Terminals and splices, wire sizes 600 MM through 500 MM, require two crimps for optimum mechanical and electrical performance. 3 anada:

atalog 805 Tooling (ontinued) AMP application tools are designed to produce a carefully controlled uniform pressure crimp, regardless of how they are powered.

Foot Operated Power Unit DYNA-RIMP Electric Hydraulic Power Unit Typical interchangable hose, head and dies not included 34979- (Hose, head and dies not included) Refer to the table below for

14 atalog 805 Tooling (ontinued) AMP application tools are designed to produce a carefully controlled uniform pressure crimp, regardless of how they are powered. All tools shown are specially designed for AMP products and are precision machined from hard tool steel. Foot Operated Power Unit DYNA-RIMP Electric Hydraulic Power Unit Typical interchangable hose, head and dies not included (Hose, head and dies not included) Refer to the table below for accessories. Power Unit Only (Includes Pressure Release) 5 Volts (60 Hz) Volts (60 Hz) Power Units Accessories For Use With Power Unit No. Accessory Description Accessory No. Remarks 7' Handle ontrol AssemblyHose & ord ' Handle ontrol AssemblyHose & ord ' Handle ontrol AssemblyHose & ord ' Foot Switch Assembly Need Hose Assembly 8' Handle ontrol AssemblyHose & ord ' Hose Assembly Foot Switch 7' Hose Assembly Assembly needed with 5' Hose Assembly these Hose Assemblies ' Hose Assembly and Way Multi-Directional Value Way Multi-Directional Value (Elec.tl) 590- For use with Way Multi-Directional Value 59 Foot Switch only 6-Way Multi-Directional Value (Elec.tl) 59- ontact AMP Incorporated for usage recommendations. Also see AMP ustomer Manual M Also see AMP ustomer Manual M 950. Note: All Hoses and Handle ontrol Assemblies have a 3 8" high male coupler (3470-) on each end. All Power Units and Heads have a 3 8" high female coupler (347-). 4 anada:

15 atalog 805 Index Note: This numerical index lists all cataloged parts by base no. only. omplete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. No. Page No. Page No. Page No. Page anada:

16 Support Services Answers to your questions are just a phone call or mouse click away. On-Line atalog If you prefer to find your information electronically, check out our web site featuring a catalog containing over 55,000 products. ustomer drawings, specifications, test reports, AD models and electrical SPIE models, P layouts and panel cutouts can be downloaded from the web site. ross references to hundreds of competitors makes it even easier to find the right part for nearly any application. anada: /help Our Specialists provide information on ditributor locations, drawing/prints, application/product specifications, P layouts, technical information, plating, electrical characteristics, dimensions, value added capabities, and 3D modeling/simulation. Tooling Assistance anada: /help Tooling support specialists will assist you in selecting hand tools, machines and applicators, identify tooling parts, and provide information about maintenance, adjustment and repair. ustomer Service anada: /help Receive price and delivery information immediately. You can also place new orders, change or expedite existing orders, and request product samples and literature through the ustomer Service Department. AMP FAX Service anada: Mexico: (toll call to USA) Documents available through AMP FAX include partnumbers/catalog pages, drawings, application/product specifications, P layouts, and distributor information. Order as many as 0 pages of information at a time, with more than 00,000 drawings, specs, and more available. 805 M GI DSP 0-0 Printed in the U.S.A. Tyco Electronics orporation, Harrisburg, PA 705

COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire)

COPALUM Terminals and Splices (For Solid & Stranded Aluminum or Copper Wire) Product Facts Bar Crimp Technique Terminals and Splices for aluminum-to-aluminum and aluminum-to-copper stripped wire applications Terminates stripped, stranded and solid (round or rectangular) aluminum