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

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

00:14wire, insertion U dy 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 solid wire,

00:49copper class B or C building wire and aluminum class B.

00:54Building wire, wire size or gauge will determine the physical wire size designation.

01:00Once the wire is identified, you can select the appropriate connector.

01:04This video will depict an installation using a four A awg aluminum terminal.

01:09For this video, we have selected an aluminum class B four A awg gauge wire installers can

01:16verify the proper connector by matching the wire size on the wire insulation to the

01:20connector. Barrel emboss Bernie aluminum lugs are dual

01:24rated and accommodate both aluminum class B and copper class B and C wire and have part number

01:31color code, dye index number, wire size markings and neural crimp bands embossed on the

01:36terminal barrel and or pad. The end cap color also corresponds to the dye

01:41color code. Chapter two proper wire stripping,

01:46wire insulation stripping is required for proper wire insertion into the connector.

01:51Proper wire stripping ensures full contact at each crimp with the wire.

01:55For optimal electrical and mechanical performance installers can find the wire strip

02:01link for the selected connector in the Burnie master catalog sales drawing or product label.

02:09If wire strip length is too long, it will expose bare wire between the barrel end and the

02:14insulation. While this does not pose a problem from an

02:17electrical or mechanical standpoint, it is not a recommended practice as exposed wires can

02:22pose a safety hazard.

02:24Wire that is exposed can be covered using burndy heat or cold shrink products.

02:30If wire strip length is too short, it will prevent the wire from fully inserting into the

02:34connector barrel preventing full crimps on the wire that could affect the integrity of the

02:39connection. When the strip length is properly sized,

02:42it ensures that no excess bare wire is exposed and the wire is fully inserted into the

02:47connector allowing four full cramps on the wire resulting in a safe and reliable connection.

02:52When stripping the insulation, be careful to avoid cutting or nicking wire strands as

02:57damaged strands can affect the integrity of the connection both from an electrical and

03:02mechanical standpoint chapter three, proper wire insertion before making a connection,

03:08verify proper wire strip length, hold the wire against the connector barrel.

03:13So the stripped insulation is budding. The barrel end visually verify the bare wire

03:18extends beyond the crimp zone as this ensures that the wire will be fully inserted into the

03:23barrel and will make full contact with the wire. When crimped wire brushing conductor is

03:28recommended for aluminum wire oxides can create an insulating barrier between the wire and

03:34connector that can minimize the conductivity in the connection for a less reliable connection.

03:40As a best practice wire brush all the conductor or wire before making a connection do not wire

03:46brush tin plated connectors.

03:48It is recommended to have an oxide inhibitor applied to aluminum conductor.

03:52So burn the aluminum connectors come prefilled with Petr A 13 oxide inhibitor and therefore

03:58are not available with an inspection window. Once the wire is scratch brushed,

04:03remove the color coded in cap and insert the wire into the connector until the wire can no

04:08longer be pushed in due to the aluminum connector barrels being prefilled with pet

04:13rocks, an installer may feel the wire stopped due to this oxide inhibitor.

04:17So the installer should apply enough force to sync the wire fully into the barrel.

04:22When this is done, excess pet rocks may discharge out of the terminal in chapter four,

04:27proper U die selection.

04:30The dy set will depend on the installation tool being used for this installation.

04:34We are using the 12 ton 750 series battery actuated Patriot T three tool which requires

04:40you dyes when selecting the proper dy set installers can verify the dye with the

04:45connector by using the unique burnie dye index numbering system and color code,

04:51dye index number 298 and white color code for this installation indicates the following

04:57information can be verified before installation.

05:01Wire material can be aluminum or copper wire type is class B wire size is four

05:07oawg color code is white connector family is Y A 28 A burnie offers both

05:14aluminum and copper dis sets. So it is important that the proper dye is

05:18selected based on the material composition of the terminal being used regardless of if the

05:24wire being installed is aluminum or copper aluminum terminals require aluminum dye sets.

05:30Chapter five proper crimping technique, inserting dyes into the installation tool for

05:36the top die half, press the die release button at the top of the tool head slide,

05:41the dye half inside the tool head groove until it is centered.

05:44Release the dye button and wiggle the dye to ensure it is properly seated for the ra M or

05:49bottom die half, press the dye release button on the side of the ram slide,

05:53the die half inside the tool head groove until it is centered.

05:57Release the dye button and wiggle the dye to ensure it is properly seated.

06:01Once both die halves are properly seated in the tool head.

06:04You are ready for cramping installation process. Once the number of crimps,

06:09crimp location and crimping sequence has been determined, you can begin the installation

06:14Bernie installation manuals and the Bernie Connect app provide you with a number of crimps,

06:19crimp location, crimping sequence and crimping diagrams to get the Bernie installation

06:24instruction manuals or the free Bernie Connect mobile app,

06:28go to the resources tab on the Bernie website to demonstrate proper

06:35crimping technique. We will be crimping an aluminum four oawg

06:38terminal with four oawg aluminum wire. We are going to show the crimping procedure for

06:44a four oawg aluminum terminal for this installation that can requires two crims place

06:51the connector against the top die haft with the bottom of the terminal pad facing the lower die

06:57haft. The top dye is stationary during tool

07:00activation allowing the installer to maintain proper connector alignment.

07:04During crimping align the first crimp closest to the terminal pad with the center of the

07:09crimp die between the 1st and 2nd embossed neural bands as shown in the illustration begin

07:15the tool's crimping cycle tool indicates a full cycle has been completed when an audible pop

07:20sound is heard. Some tools also depict a green indicator light

07:26as a secondary indicator of a completed crimp.

07:29A red light would indicate an incomplete crimp.

07:33Once the first crimp is complete, retract the tool ramp and align the second crimp closest to

07:38the wire end with the center of the crimp dye between the 3rd and 4th crimp bands as shown in

07:43the illustration. Once you have finished your two crimps,

07:46the installation is complete, you can verify that a proper installation has been made by the

07:51presence of the correct dye emboss on the connector falling within the crimp zones.

07:57The crimping orientation during an installation on a seamless compression terminal is not

08:02critical from an electrical or mechanical performance perspective.

08:06However, crimping in the orientation recommended provides a uniform and clean

08:10looking connection crimping. Contrary to birdie's recommendations may cause

08:15flash to extrude vertically on the terminal which could prevent the connector from sitting

08:19flush on mounting surfaces.

08:23Chapter six, proper inspection inspectors can validate proper terminal installation with the

08:29use of U dyes visually and physically visual inspection inspectors can visually see the

08:36dye index number embossed on each crimp of the connection.

08:39Dye index emboss provide the inspectors with wire material,

08:43either copper or aluminum wire type. In this example,

08:47class B wire size. In this example, for a awg dy index number on

08:54the emboss matches with the markings on the terminal.

08:56In this case, 298 color code in this instance, white and connector family.

09:02In this example, Y A 28 A as indicated on the terminal emboss

09:09inspection with physical measurement tools.

09:12Physical inspection of A crimp can be done with the use of the wire mic C I or calipers,

09:17wire mic C I can be used as a you dye post primp measurement tool.

09:21Place the wire mic on the crimp, read the dye catalog number indicated on the tool and verify

09:27that dye catalog number with the dye used based on the dye index number and color code.

09:32The Burnie Connect app provides the post print dimension range place calipers on the prim and

09:38verify the readings fall within the proper post print dimensions.

09:42This concludes the aluminum terminal installation training video.