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696912-1

P1-P3P4-P6
Application Specification
1 of 6
© 2016 TE Connectivity family of companies
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.
PRODUCT INFORMATION
1-800-522-6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.te.com.
114-2134
11 NOV 16 Rev F
NOTE
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches].
Unless otherwise specified, dimensions have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2°. Figures and
illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of COPALUM sealed terminals and splices, which are
especially suited for the aerospace industry. These terminals and splices are designed to be terminated to fine
stranded aluminum (Al) wire sizes 8.6 to 110.9 mm
2
[8 to 4/0 AWG] and copper (Cu) wire sizes 4.8 to 85.9 mm
2
[10 to 3/0 AWG]. The terminals are available in a variety of ring tongue lengths, shapes, and stud hole sizes.
Markings on the terminals and splices indicate the accepted wire sizes and types (Al for aluminum and Cu for
copper).
Each sealed terminal and splice has a barrier that helps locate and seal the wire barrel and a funnel lead-in
chamfer in the wire barrel that helps guide the wire. A perforated insert in the wire barrel causes a wiping action
on the wire during crimping, removing oxides and forming a solid electrical bond between the wire and terminal
or splice.
Standard butt splices have a wire barrel at each end and are used for joining aluminum-to-aluminum,
aluminum-to-“down size” copper, or copper-to-copper wires. Transitional butt splices have a wire barrel at each
end and are used for joining aluminum and copper wires. A blue ring around one wire barrel (which has no
perforated insert) indicates the copper wire end of the splice.
All sealed terminals and splices are designed to be crimped with precision dies and a power-assist unit, which
perform a unique dry crimp that removes oxides to expose uncontaminated metal surfaces and seals the
termination to prevent oxidation.
When corresponding with personnel, use the terminology provided in this specification to facilitate your
inquiries for information. Basic terms and features of this product are provided in Figure 1.
Figure 1
COPALUM* Sealed
Terminals and Splices
114-2134
Rev F
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The circumferential crimp alignment knurl and asterisk alignment mark featured on each wire barrel of the
splice indicates the direction that the splice should be placed in the dies when crimping the splice.
NOTE
Copper wire has a greater electrical conductivity, density, and weight than aluminum wire of the same size. Because of this
differentiation, there is a down size difference from an aluminum to copper wire. Size differences are given in Figure 2.
2. REFERENCE MATERIAL
2.1. Revision Summary
Deleted artwork and table information in Figure 6 and added NOTE for clarification.
2.2. Customer Assistance
Reference Product Base Part Number 277147 and Product Code 3015 are representative of COPALUM sealed
terminals and splices. Use of these numbers will identify the product line and help you to obtain product and
tooling information when visiting
www.te.com or calling the number at the bottom of page 1.
2.3. Drawings
Customer drawings for product part numbers are available from
www.te.com. Information contained in the
customer drawing takes priority.
2.4. Specifications
Product Specifications (108-series) provide product performance and test results. Product specifications that
pertain to this product are:
108-11011 Sealed COPALUM Terminals and Splices, Aluminum Wire
108-11011-1 Sealed COPALUM Terminals and Splices, Copper Wire
108-11011-2 Sealed COPALUM 90-Degree Flag Terminal, Aluminum Wire
108-11011-3 Sealed COPALUM Transitional Butt Splices, Copper and Aluminum Wire
2.5. Publications
Publications developed by SAE International available for this product are:
SAE AS70991 Terminals: Lug and Splice, Crimp Style, Aluminum, For Aluminum Aircraft Wire
SAE AS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy
2.6. Instructional Material
Instruction sheets (408-series) provide product assembly instructions or tooling setup and operation procedures
and customer manuals (409-series) provide machine setup and operating procedures. Instructional material
that pertain to this product are:
408-2281 Crimping Die Assemblies for COPALUM Sealed Terminals and Splices
408-2453 Hydraulic Crimping Head 69066
408-7424 Checking Terminal Crimp Height or Gaging Die Closure
408-8909 Inspection and Servicing Hydraulic Crimping Heads 1752787-1 and 1752877-1
408-8914 Hydraulic Crimping Head 1752787-1
408-8956 Hydraulic Crimping Head 1752877-1
408-9535 Hydraulic Crimping Head 58422-1
409-1950 Heavy-Duty Electric Hydraulic Pumps 69120-1 and 69120-2
409-5860 Hydraulic Hand Pump 314979-1
409-10081 Electric Hydraulic Pumps 1804700-1 and -2
3. REQUIREMENTS
3.1. Safety
Do not stack product shipping containers so high that the containers buckle or deform.
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Rev F
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3.2. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the product
material.
B. Shelf Life
The product should remain in the shipping containers until ready for use to prevent deformation to
components. The product should be used on a first in, first out basis to avoid storage contamination that
could adversely affect performance.
C. Chemical Exposure
Do not store product near any chemical listed below as they may cause stress corrosion cracking in the
material.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
3.3. Wire Selection and Preparation
DANGER
To avoid personal injury, DO NOT use larger or smaller aluminum or copper wire sizes than those designated.
The terminal or splice selected will be determined by the wire size and type and wire insulation diameter which
is given on the customer drawing of each terminal and splice. For standard butt splices, a cross-reference of
wire size marking-to-use is given in Figure 2.
SPLICE WIRE SIZE MARKING
STANDARD BUTT SPLICE USE
ALUMINUM-TO-DOWN
SIZE COPPER
4/0 AL-3/0 CU
4/0 to 3/0
3/0 AL-2/0 CU
3/0 to 3/0
2/0 to 2/0
3/0 to 2/0
2/0 AL-1/0 CU
2/0 to 1/0
1/0 AL-2 CU
1/0 to 20
2 AL-4 CU
2 to 2
4 to 4
2 to 4
4 AL-6 CU
4 to 6
6 AL-8 CU
6 to 8
8 AL-10 CU
8 to 8
10 to 10
08 to 10
Figure 2
The strip length for the wire will depend on the number of insulation layers covering the wire. Wire sizes in
metric, AWG, and circular mil area (CMA) comparison and the wire strip length is given in Figure 3.
Figure 3 (cont’d)
P1-P3P4-P6

696912-1

Mfr. #:
Buy 696912-1
Manufacturer:
TE Connectivity / AMP Connectors
Description:
Heavy Duty Power Connectors COPALUM SLD BRZD R 4/0AL 90
Lifecycle:
New from this manufacturer.
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