Al and AlCu terminals and connectors mm²

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Easter Mathews
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1 Al and AlCu terminals and connectors ² General information 2 Al terminals ² 3 Through connectors with partition ² 4 Through connectors without partition ² Through connectors with partition and for different areas ² 6 AlCu, bi-metallic terminals ² 7 AlCu bi-metallic pin terminals, ² 8 AlCu bimetallic through connectors ² 9 s 10 :1

2 Terminals and connectors Elpress terminals and connectors are made from pure aluminium 99.7% and, in case of bi-metal types, also from electrolytic copper. The standard range size is 16 to 1200 ² but a variety of customer specified types also exists. The Elpress Crimp System fits compacted/un-compacted stranded as well as solid Al conductors in accordance with IEC that in case of solid conductors one area step down is used as marked on the barrel. In case of sectorshaped conductors, pre-rounding is required and performed with tools within the Crimp System. This makes it possible to crimp the terminal in such a position that twisting is minimised when connecting to the bus bar or apparatus. Two indents are always made in the order shown in the picture below. TERMINALS: Markings on Al and AlCu terminals Barrel marking, example: ALU18-R18-P32 (Elpress logotype) T2 SOLID 240 ALU18 = Al-conductor, ² R18 = id-no. for punch and matrix for pre-rounding P32 = id-no. for punch and matrix for crimping T2 = Finnish temperature class SOLID 240 = suitable size on solid conductor Palm marking: (Elpress logotype) 16 = M-screw size THROUGH CONNECTORS: Markings on Al and AlCu connectors Copper side of AlCu type Example: Cu (Elpress logotype) Cu240 = Cu conductor, ² 30 = id-no. for hexagonal crimp die Al connector or Al side of AlCu connector Example: ALU300-R21-P36 (Elpress logotype) T2 ALU300 = Al conductor, ² R21 = id-no. of punch and matrix for pre-rounding P36 = id-no. of punch and matrix for crimping T2 = Finnish temperature class All Al or AlCu types Al terminals type AK are mainly used for connection to Al bus bars, apparatus terminals or such. Bi-metal terminals type AKK are mainly used for connection to Cu busbars, apparatus terminals or such. Al connectors type AS are used to connect two Al conductors, also of different sizes. Bi-metal connectors type AKS are used to connect an Al and a Cu conductor also of different sizes. Bi-metal pin connectors type AKP are used to connect Al conductors to mechanical clamp type connections for round Cu pins. Crimp sequence when making indent crimping on aluminium. Marking of Al and AlCu terminals Elpress System for marking of Al and AlCu terminals and connectors shows the stranded and solid metric conductor size and reference to the id-numbers of the appropriate Elpress pre-rounding and crimp tools. Do not use other crimp tools! The T2-mark is a reference to an earlier Finnish standard. On bi-metal connectors there is also a tool id-reference to the hexagonal die to be used for the Cu-crimp. Palm holes to ISO 273 Screw dimension Palm hole tol H13 (Ø ) M 3 3,2 M 4 4,3 M,3 M 6 6,4 M 8 8,4 M 10 10, M M M M 24 2 :2

3 Al terminals ² used to terminate Al-conductors to Al busbars two adjacent crimps are necessary - crimp sequence see picture other designs, see : 1 Stranded, compacted conductor 2 Unholed palm 3 For solid conductors only 4 Outer barrel diam. 2. Outer barrel diam. 44. stranded, ² W d N N 1 L AK (16) 16,0,9 8, 9, :7 9:11 9:16 9:27-33 AK (16) 16,0,9 8, 9, AK ,0 6,8 8, 9, AK ,0 6,8 8, 9, AK , 11,0 14, AK , 11,0 14, AK ,6 11,0 14, AK ,6 11,0 14, AK ,6 14,0 1, AK ,3 11,0 14, AK ,3 11,0 14, AK ,3 14,0 1, AK , 14,0 1, AK , 14,0 1, AK , 14,0 1, AK ,0 14,0 1, AK ,0 14,0 1, AK ,8 14,0 1, AK ,8 14,0 1, AK , AK ,6 16,0 19, AK ,6 16,0 19, AK ,6 16,0 19, AK ,8 16,0 19, AK ,8 16,0 19, AK SOLID , AK SOLID , AK , AK , AK AK , AK , AK AK 00A AK 00A AK 00A/ * ,4 AK 00A/ * ,4 AK 00B AK 00B AK 00B * AK 00B * AK 630A/ * ,2 AK 630A/ * ,2 AK 800/ * ,2 9:36 AK 800/ ,2 AK 1000/ * ,2 AK 1000/ * ,2 AK * ,2 * corresponds to the full palm length. ** Outer diameter 2. Also available with outer diameter 44 - see AK00B-xx. :3

4 Through connectors with partition ² used mainly for connecting two Al-conductors of the same size to each other two crimps on each side are necessary, crimp sequence see picture partition in the middle to prevent fluid flow stranded, ² ² d D L AS 16 2 (+16),9 13, :7 9:11 9:16 9:27-33 AS 2 3 6,8 13, :7 AS 3 0 8, AS , AS , AS , AS , AS , AS , AS , AS 300 SOLID AS AS AS 00A AS 00B AS 630A / AS 630 / AS 800 / :36 1 AS 1000 / AS If other combinations are needed, contact Elpress. 1 Stranded, compacted conductor 4 Barrel outer diam Unholed palm Barrel outer diam For solid conductors only :4

Through connectors without partition 0-240 ² used mainly for connecting two Al-conductors of the same size to each other two crimps on each side are necessary, crimp sequence see picture no partition

5 Through connectors without partition ² used mainly for connecting two Al-conductors of the same size to each other two crimps on each side are necessary, crimp sequence see picture no partition in the middle stranded, ² ² d D L AS 0H 70 9, :11 9:16-33 AS 70H 9 11, AS 9H , AS 120H 10 14, AS 10H 18 1, AS 18H , AS 240H 19, Other designs of Al and AlCu terminals and connectors In cases where other hole patterns, palm sizes, assembly angles, etc. are needed, a broad variety of customer specified items may be produced. Some examples are indicated here: AKK00A/ x4-3 resp. AK18-14x2-40. :

6 Through connectors with partition and for different areas ² used mainly for connecting two Al-conductors of different sizes to each other two crimps on each side are necessary, crimp sequence see picture partition in the middle to prevent fluid flow stranded, ² ² L d 1 D 1 d D AS ,9 13,0 6,8 13,0 48 9:11 9:16 9:27-33 AS ,8 13,0 8, AS ,8 13,0 9, AS , 20 9, AS , , AS ,8 13,0 12, 2 24 AS , 20 12, 2 24 AS , , 2 24 AS , , 2 24 AS , AS ,6 20 1, AS ,3 20 1, AS , 2 1, AS ,0 2 1, AS , 2 17, AS ,8 2 17, AS , 2 19, AS ,0 2 19, AS ,8 2 19, AS , , AS , AS Other measures, see corresponding connector on previous s. If other combinations are needed, contact Elpress. :6

AlCu, bi-metallic terminals 16-1200 ² used primarily to terminate Al-conductors to Cu appliance studs, Cu bus bars, etc.

7 AlCu, bi-metallic terminals ² used primarily to terminate Al-conductors to Cu appliance studs, Cu bus bars, etc. two adjacent crimps are necessary - crimp sequence, see picture 1 Stranded, compacted conductor 2 Unholed palm 3 For solid conductors only 4 Outer barrel diam. 2. Outer barrel diam. 44. stranded, ² W d N N 1 L AKK (16) 16,0,9 8, 10, :7 9:11 9:16 9:27-33 AKK ,0 6,8 8, 10, AKK ,0 11, 1, 7 24 AKK , 12, 12, AKK ,6 12, 12, AKK ,6 12, 12, AKK ,6 12, 12, AKK ,3 12, 12, AKK ,3 12, 12, AKK ,3 12, 12, AKK , 1,0 1, AKK , 1,0 1, AKK , 1,0 1, AKK , 1,0 1, AKK ,0 1,0 1, AKK ,0 1,0 1, AKK ,0 1,0 1, AKK ,8 1,0 1, AKK ,8 1,0 1, AKK ,8 1,0 1, AKK ,6 1,0 1, AKK ,6 1,0 1, AKK ,6 1,0 1, AKK ,8 1,0 1, AKK ,8 1,0 1, AKK ,8 1,0 1, AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK , 18, 1 6 AKK 00A AKK 00A AKK 00A/ * AKK 00A/ * AKK 00B AKK 00B AKK 00B * AKK 00B * AKK 630A/ * 239 1,2 AKK 630A/ * 239 1,2 AKK 800/ * 263 9:36 1,2 AKK 800/ * 27 1,2 AKK 1000/ * 263 1,2 AKK 1000/ * 27 1,2 AKK * 310 1,2 * the full palm length :7

AlCu bi-metallic pin terminals, 16-300 ² used to connect Al conductors to mechanical clamp type connections for round Cu pins.

8 AlCu bi-metallic pin terminals, ² used to connect Al conductors to mechanical clamp type connections for round Cu pins. two adjacent crimps are necessary - crimp sequence, see picture stranded, ² ² e d D L 1 L AKP 16 2 (16) 6,0,9 13, :7 9:11 9:16 9:27-33 AKP 2 3 6,0 6,8 13, :7 AKP 3 0 9,0 8, AKP ,0 9, AKP ,0 11, AKP ,0 12, AKP ,0 14, AKP ,0 1, AKP ,0 17, AKP ,0 19, AKP , Transition connectors for Al conductors 16-9 ² to Cu solid conductors 10 ² adapter connector from stranded Al-conductor to solid Cu-conductor 10 2 (e.g. Excel, Excelett) two crimps are necessary for both Al and Cu, crimp sequence see picture (equal order for Cu), ², Al-Cu Al ² d d 1 L AKS 16-10S 2 (16),9 4, :7 9: AKS 2-10S 3 6,8 4, :7 1 AKS 3-10S 0 8, 4, AKS 0-10S 70 9,6 4, AKS 70-10S 9 11,3 4, AKS 9-10S , 4, Make two crimps also on the Cu-side. :8

AlCu bimetallic through connectors 16-400 ² connect Al-conductors to Cu-conductors stranded/solid Al-conductors, stranded/flexible Cu conductor two adjacent crimps for Al, see picture; normally one

9 AlCu bimetallic through connectors ² connect Al-conductors to Cu-conductors stranded/solid Al-conductors, stranded/flexible Cu conductor two adjacent crimps for Al, see picture; normally one for Cu, see note when crimping the Cu-part, place the dies between the circular groove on the Cu-barrel and the edge, ², Al-Cu Al ² d d 1 L AKS (16),9, :7 9:11 9:16 9:27-33 AKS ,8, AKS ,8 6, AKS ,, AKS , 6, AKS , 8, AKS ,6, AKS ,6 6, AKS ,6 8, AKS ,6 9, AKS ,6 11, AKS ,3 9, AKS ,3 11, AKS ,3 13, AKS ,, AKS , 6, AKS , 8, AKS , 9, AKS , 11, AKS , 13, AKS , 1, AKS ,0 11, AKS ,0 13, AKS ,0 1, AKS ,0 17, AKS ,8 8, AKS ,8 9, AKS ,8 11, AKS ,8 13, AKS ,8 1, AKS ,8 17, AKS ,8 19, AKS ,6 1, AKS ,6 17, AKS ,6 19, AKS , AKS ,8 9, AKS ,8 11, AKS ,8 13, AKS ,8 1, AKS ,8 17, AKS ,8 19, AKS , AKS A 19,8 22, AKS , AKS AKS A 22 22, 12 9 AKS , AKS AKS A 2 22, AKS A 2 24, 12 6 :9

High current plug-in connector

2017.12 High current plug-in connector with a wrong insertion prevention mechanism Plug-in Connector (A Wrong Insertion Prevention Mechanism) Features of the high current plug-in connector with a wrong