00:06The burnie copper terminal installation training video topics.

00:11We will discuss compression terminal selection, wire, stripping,

00:14wire, insertion you dye selection crimping technique including number of crimps,

00:20crimp placement and crimping sequence inspection.

00:25Chapter one proper connector selection, proper terminal selection is determined by the wire

00:30being terminated and the mounting requirements for the application.

00:34In this video, we are only focused on the wire termination portion of the terminal.

00:39Identify the wire material, copper or aluminum as this will determine the connector product

00:44line to be used to terminate. The wire wire types include copper,

00:48solid wire, copper class B or C building wire, copper, high strand count,

00:54flexible wire classes, Ghikm or DLO and aluminum class B.

01:01Building wire, wire size or gauge will determine the physical wire size designation.

01:07Once the wire is identified, you can select the appropriate connector.

01:11This video will depict an installation using both a standard and long barrel terminal.

01:16For this video, we have selected a copper class B four A AWG gauge wire installers can

01:23verify the proper connector by matching the wire size on the wire insulation to the

01:27connector barrel ink marking and or the info embossed on the terminal pad.

01:32Burnie code lugs accommodate both class B and C wire stranding and have solid color code bands

01:38with knockout lettering.

01:41Chapter two, proper wire stripping, wire insulation stripping is required for proper

01:47wire insertion into the connector. Proper wire stripping ensures full contact at

01:51each crimp with the wire. For optimal electrical and mechanical

01:55performance installers can find the wire strip link for the selected connector in the burnie

02:01master catalog sales drawing or product label.

02:06If wire strip length is too long, it will expose bare wire between the barrel end and the

02:12insulation. While this does not pose a problem from an

02:15electrical or mechanical standpoint, it is not a recommended practice.

02:19As exposed wires can pose a safety hazard.

02:22Wire that is exposed can be covered using burny heat or cold shrink products.

02:27If wire strip length is too short, it will prevent the wire from fully inserting into the

02:32connector barrel preventing full crimps on the wire that could affect the integrity of the

02:36connection. When the strip length is properly sized,

02:39it ensures that no excess bare wire is exposed and the wire is fully inserted into the

02:44connector allowing four full cramps on the wire resulting in a safe and reliable connection.

02:50When stripping the insulation, be careful to avoid cutting or nicking wire strands as

02:55damaged strands can affect the integrity of the connection both from an electrical and

02:59mechanical standpoint.

03:01Chapter three, proper wire insertion before making a connection.

03:06Verify proper wire strip length, hold the wire against the connector barrel.

03:10So the stripped insulation is butting the barrel length visually verify the bare wire

03:16extends beyond the crimp zone as this ensures that the wire will be fully inserted into the

03:21barrel and will make full contact with the wire. When crimped chapter four,

03:26proper you dye selection, the dye set will depend on the installation tool being used for

03:32this installation. We are using the 12 ton 750 series battery

03:36actuated Patriot T three tool which requires U dyes.

03:40When selecting the proper dy set installers can verify the dye with the connector by using the

03:45unique burnie dye index numbering system and color code dye index number 15 and purple color

03:52code for this installation indicates the following information that can be verified

03:56before installation.

04:00Wire material is copper wire type is class B wire size is four A AWG

04:07color code is purple connector family is Y A 28 chapter five

04:14proper crimping technique.

04:16Inserting dyes into the installation tool for the top die half press the die release button

04:22at the top of the tool head slide, the die half inside the tool head groove until it is center

04:28release the dye button and wiggle the dye to ensure it is properly seated for the ra M or

04:33bottom die half press the die release button on the side of the ra M slide,

04:37the die half inside the tool head groove until it is centered,

04:41release the dye button and wiggle the dye to ensure it is properly seated.

04:45Once both die hals are properly seated in the tool head,

04:49you are ready for crimping installation process. Once the number of crimps crimp location and

04:54crimping sequence has been determined, you can begin the installation,

04:57Bernie installation manuals. And the Bernie Connect app provide you with a

05:02number of crimps, crimp location, crimping sequence and crimping diagrams to get the

05:07Bernie installation instruction manuals or the free Bernie Connect mobile app.

05:11Go to the resources tab on the Bernie website to demonstrate

05:18proper crimping technique. We will be crimping both a standard and long

05:21barrel terminal. We are going to show the crimping procedure for

05:24a standard barrel terminal for this installation.

05:27The connector requires one crimp place the connector against the top die half with the

05:32bottom of the terminal pad facing the lower die half.

05:37The top dye is stationary during tool activation allowing the installer to maintain

05:42proper connector alignment during crimping align the connector crimp zone to be centered

05:47with the middle of the top dye.

05:48Begin the tool's crimping cycle tool indicates a full cycle has been completed when an audible

05:54pop sound is heard.

05:58Some tools also depict a green indicator light as a secondary indicator of a completed crimp.

06:05A red light would indicate an incomplete crimp.

06:08You can verify that a proper installation has been made by the presence of the correct dye

06:13emboss on the connector falling within the crimp zones.

06:18Long barrel terminals, we are going to show the crimping procedure for a long barrel terminal.

06:23For this installation, the connector requires two cramps,

06:26place the connector against the top dye half with the bottom of the terminal pad facing the

06:31lower die half. The top dye is stationary during tool

06:34activation allowing the installer to maintain proper connector alignment.

06:38Crimping align the first crimp closest to the terminal pad with the center of the crimp dive

06:43between the 1st and 2nd crimp bands. As shown in the illustration begin,

06:48the tool's crimping cycle tool indicates a full cycle as completed when an audible pop sound is

06:53heard. Once the first crimp is complete,

06:57retract the tool ramp and align the second crimp closest to the wire end with the center

07:02of the crimp dye between the 3rd and 4th crimp bands.

07:05As shown in the illustration. Once you have finished your two crimps,

07:08the installation is complete, you can verify that a proper installation has been made by the

07:13presence of its direct dye emboss on the connector falling within the crimp zones.

07:20The crimping orientation during an installation on a seamless compression terminal is not

07:25critical from an electrical or mechanical performance perspective.

07:28However, crimping in the orientation recommended provides a uniform and clean

07:33looking connection crimping. Contrary to Bernie's recommendations may cause

07:38flash to extrude vertically on the terminal which could prevent the connector from sitting

07:42flush on mounting surfaces.

07:45Chapter six proper inspection inspectors can validate proper terminal installation with the

07:51use of U dyes visually and physically visual inspection inspectors can visually see the

07:58dye index number embossed on each crimp of the connection.

08:02Dye index emboss ments provide the inspectors with wire material.

08:06In this example, copper wire type.

08:09In this example, class B wire size. In this example,

08:13four A AWG dy index number on the emboss matches with the markings on the terminal.

08:20In this case, 15 color code in this case, purple connector family.

08:25In this example, Y A 28 as indicated on the terminal markings.

08:31Inspection with physical measurement tools, physical inspection of A crimp can be done with

08:37the use of the wire mic C I or calipers wire mic C I can be used as a you dye post primp

08:43measurement tool. Place the wire mic on the crimp,

08:46read the dye catalog number indicated on the tool and verify that dye catalog number with

08:51the dye used based on the dye index number and color code.

08:55The Burnie Connect app provides the post print dimension range place calipers on the print and

09:00verify the readings fall within the proper post print dimensions.

09:04This concludes the copper code terminal installation training video.