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COMPRESSION
CONNECTORS
BURNDY’s compression connectors are
designed for reliable and controllable electri-
cal connections. The complete installation is
fully inspectable. They are high conductivity
copper and operate cooler than the wire on
which they are installed. The connectors
withstand a wide range of electrical and envi-
ronmental conditions, including current
surges, temperatures, corrosion and vibra-
tions, for a wide variety of applications.
These features mean a consistently high
quality connection at a low installed cost.
Copper compression connectors are manu-
factured from high-conductivity electrolytic
copper. The connectors are normally tin-
plated, lead-plated, or plated with propri-
etary BURNDY
®
brite finish to provide
durable long-lasting corrosion resistance.
The connector design has been matched to
the cable size to provide the necessary phys-
ical strength requirements for reliable electri-
cal performance.
Aluminum compression connectors are man-
ufactured from high conductivity, high purity
wrought aluminum. They are designed with
sufficient mass and are electro-tin plated to
minimize corrosion due to galvanic action
between dissimilar metals. The connector
barrels are pre-filled with PENETROX
®
,
BURNDY’s oxide inhibiting compound.
PENETROX
®
contains homogeneously sus-
pended metallic particles which penetrate
the wire’s oxides to establish excellent conti-
nuity between the individual strands and the
connector barrel for a low-resistance con-
nection. PENETROX
®
maintains an air-tight
connection. Each barrel end is covered with
a color-coded plastic dust cap which pre-
vents foreign matter from entering the con-
nector before it is used. The connector
design has been engineered to match the
cable size to provide the necessary physical
strength requirements for reliable electrical
performance.
SELECTION AND USE
Copper compression connectors are recom-
mended for use on copper conductors.
Aluminum compression connectors are
recommended for use on aluminum conduc-
tors. Dual-rated aluminum compression
connectors may be used on both copper and
aluminum conductors.
Two basic compression designs are avail-
able: Circumferential and indent.
TOOLING
Tooling systems are essential for proper
installation of a compression connector.
Since connectors and dies are designed as a
unit for specific wire sizes, only the recom-
mended tools and dies should be used. Most
aluminum and copper HYLUG™ terminals
and HYLINK™ splices are marked with a die
index number and are color-coded to identi-
fy the correct installation die. Dies marked
with the matching die index number and
color can be used to install the connector.
BURNDY
®
tooling installs a wide range of
connectors, is reliable, cost effective, and
precision engineered for durable, long-last-
ing service and quality connections. The
tools include small plier types, full cycle
ratchet designs and hydraulically-powered
HYPRESS™ heads and new Battery
Actuated Tools. Some have permanent die
grooves or adjustable dies, while others
require a change of die sets or nest die for
each connector size. BURNDY’s recom-
mended tools achieve crimp performance
consistent with UL and other industry stan-
dards. Since several tools are suitable for
most connectors, the most economical and
practical tool can be chosen for each appli-
cation.
INDUSTRY STANDARDS
BURNDY’s compression terminals, splices
and tap connectors requiring third party test-
ing and approval are listed by Underwriters’
Laboratories, Inc. Many have also received
CSA approval and are approved under MIL-
T-7928 and other military standards. All
conform to applicable sections of the
National Electrical Code.
BURNDY
®
also offers connectors and
splices which meet the (LOCA Seismec and
Aging) requirements of IEEE standards 323,
383 and 344 for class 1E critical circuits for
use in Nuclear Utility Applications.
Certification to 10CFR50 and 10CFR21 avail-
able.
Detail catalog listings should be consulted to
obtain the appropriate standards for each
connector and splice.
After compression, virtually all the air is
removed leaving a tight homogeneous mass
of connector and conductor.
Circumferential
compression is solid
and symmetrical.
No sharp Flash.
Indent compression.
The connector is swaged
to the conductor.
The circumferential crimp design is recom-
mended for color coded connectors in low
and high voltage applications. Die index
number embossment provides an easy
inspection where required to verify the use of
the proper connector/die combination. It is
also recommended for insulated connectors
and for terminating flexible and welding
cables.
The circumferential crimp design dies com-
press cable strands into polygonal shapes
forming intimate contact with each other and
the connector barrel. This compression
forms a tight homogeneous mass with virtu-
ally no air pockets. The circumferential crimp
provides an excellent electrical connection
with high pull-out values. The circumferential
crimp is ideal for high voltage applications
leaving the connector barrel symmetrical,
which is easier to insulate.
The indent type crimp can be used in virtual-
ly any application except polyvinylchloride
(PVC) insulated terminals and splices. It is an
excellent means of terminating flexible, extra
flexible and welding cables. The indentor
compresses the cable strands to form inti-
mate contact with each other and the
connector barrel. The result is an excellent
electrical connection with high pull-out
strength. Laboratory work testing curves
established the proper depth and shape of
indent for each type of connector and wire
combination.
Blue highlighted items are industry standard and most frequently ordered.
Canada: 1-800-387-6487
www.burndy.com
US: 1-800-346-4175
C-4
Compression Connections
BURNDY
®