ASI 2190190 A5-M10 Ring Terminal User Manual

1. Product Overview

The ASI 2190190, Type A5-M10, is a non-insulated ring terminal designed for electrical connections. This product is supplied in a package of 100 units. These terminals are UL Listed for use with 4 AWG (American Wire Gauge) conductors and are compatible with 3/8-inch stud sizes. They are engineered for crimping applications using appropriate tools available from Automation Systems Interconnect (ASI).

The A-M series ring terminals are manufactured from electrolytic copper, which undergoes a heat treatment (annealing) process. This process enhances the terminal's strength, particularly at the junction between the crimp barrel and the ring tongue. The wire barrel of this 4 gauge crimp lug features an optimized length to facilitate ideal crimping, and an inspection hole is incorporated at the end of the barrel to allow for visual verification of proper wire insertion. To prevent oxidation and ensure suitability for most environments, this 4 AWG ring terminal, designed for a 3/8-inch stud, is tin-plated.

Figure 1.1: ASI A5-M10 Non-Insulated Ring Terminal. This image displays a single ASI A5-M10 non-insulated ring terminal. The terminal is made of tin-plated copper, featuring a circular eyelet for a 3/8-inch stud connection and a cylindrical barrel for crimping 4 AWG wire. A small inspection hole is visible on the barrel, allowing for verification of proper wire insertion.

2. Safety Information

Always observe standard electrical safety precautions when working with electrical components and wiring. Failure to do so may result in personal injury or damage to equipment.

• Ensure power is disconnected before working on any electrical circuit.
• Use appropriate personal protective equipment (PPE), such as safety glasses and insulated gloves, if required.
• Verify that the wire gauge and stud size match the specifications of the terminal.
• Use only crimping tools designed for the specific type and size of terminal to ensure a secure and reliable connection.
• Consult local electrical codes and regulations for proper installation practices.

3. Installation and Setup

Proper installation of the ring terminal is crucial for a reliable electrical connection. Follow these steps for optimal results:

1. Wire Preparation: Strip the insulation from the 4 AWG wire to the appropriate length, ensuring that the bare conductor will fully enter the terminal's wire barrel without extending beyond the inspection hole. Avoid damaging the wire strands during stripping.
2. Wire Insertion: Insert the stripped wire fully into the terminal's wire barrel. Utilize the inspection hole to confirm that the wire conductor is properly seated and visible.
3. Crimping: Select a crimping tool specifically designed for 4 AWG non-insulated terminals. ASI offers compatible cordless hydraulic crimping tools such as B15MA, B35-50MA, B500A, and B1500A. Position the terminal and wire within the crimping tool's dies according to the tool's instructions. Apply firm and consistent pressure to create a secure crimp. A properly crimped connection should be mechanically strong and electrically sound.
4. Connection: Once crimped, secure the ring terminal to the 3/8-inch stud using an appropriate fastener (e.g., nut and washer), ensuring a tight and stable connection.

4. Operating Principles

The ASI A5-M10 ring terminal functions as a robust electrical connector, providing a secure and low-resistance pathway for current flow. Once properly crimped onto a 4 AWG conductor and fastened to a 3/8-inch stud, it establishes a permanent and reliable connection. The tin-plating on the copper terminal helps to maintain conductivity and resist environmental degradation, ensuring consistent performance over time.

5. Maintenance

These non-insulated ring terminals are designed for long-term reliability with minimal maintenance. However, periodic inspection can help ensure continued performance:

• Visual Inspection: Periodically inspect installed terminals for any signs of corrosion, discoloration, or mechanical damage.
• Connection Integrity: Ensure that the connection to the stud remains tight. Loose connections can lead to increased resistance and heat buildup.
• Storage: Store unused terminals in a dry environment, away from moisture and corrosive substances, to prevent oxidation of the tin-plated copper.

6. Troubleshooting

While ring terminals are generally straightforward components, issues can arise from improper installation or environmental factors:

• Poor Electrical Connection: If a connection exhibits high resistance or heat, it may indicate a poor crimp or a loose connection to the stud. Re-crimp the terminal if necessary, ensuring proper wire insertion and using the correct crimping tool. Tighten the stud connection.
• Corrosion: Although tin-plated, extreme environments can still lead to corrosion. If corrosion is observed, the terminal may need to be replaced. Ensure proper environmental sealing if the application requires it.
• Wire Pull-Out: If the wire pulls out of the terminal, it indicates an insufficient crimp. Ensure the wire is fully inserted and use the correct crimping tool with adequate pressure.

7. Specifications

8. Warranty and Support

Specific warranty information for the ASI 2190190 A5-M10 Ring Terminals is not provided in the available product data. For detailed warranty terms, technical support, or inquiries regarding compatible crimping tools, please contact Automation Systems Interconnect (ASI) directly through their official website or customer service channels.