BURNDY®Products
Compression
C-4
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 with-
stand a wide range of electrical and environ-
mental conditions, including current surges,
temperatures, corrosion and vibrations, 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 proprietary
BURNDY®brite finish to provide durable
long-lasting corrosion resistance. The con-
nector design has been matched to the cable
size to provide the necessary physical
strength requirements for reliable electrical
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 continuity
between the individual strands and the
connector barrel for a low-resistance connec-
tion. PENETROX®maintains an air-tight
connection. Each barrel end is covered with a
color-coded plastic dust cap which prevents
foreign matter from entering the connector
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 perfor-
mance.
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 available:
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 identify
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 pre-
cision engineered for durable, long-lasting
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 recommend-
ed tools achieve crimp performance consis-
tent with UL and other industry standards.
Since several tools are suitable for most
connectors, the most economical and practi-
cal tool can be chosen for each application.
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 available.
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 virtually 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 virtually
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.