ABB - Installation Products 61963 - Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 400 kcmil to Copper Pigtail Wire Size 250 kcmil, Die Code 87H, Die Color Code Brown
ABB - Installation Products

61963

UPC: 786210619637


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Overview

The ABB Bi-Metal Pin Connector (SKU: 61963) from ABB Installation Products provides a reliable, UL486A/B-listed solution for joining aluminum cables (400 kcmil) to copper pigtails (250 kcmil) in industrial, utility, and commercial electrical systems. Engineered with a bi-metal design, this connector ensures seamless compatibility between dissimilar metals, preventing galvanic corrosion and maintaining long-term electrical integrity. Rated for 600V maximum and 90°C temperature, it meets the demands of high-current applications while ensuring safety and compliance with NEC standards. Key specifications include a die code of 87H (brown color-coded) for easy identification and crimping with compatible tools such as the N1240. The connector features a stranded copper pin, tin-plated for corrosion resistance, and is supplied with a PVC insulating cover to protect against electrical hazards and mechanical damage. The connector body is coated with an oxide inhibitor to enhance conductivity and durability in harsh environments. Ideal for terminating aluminum conductors in power distribution, motor control centers, and renewable energy systems, the 61963 connector delivers consistent performance with circumferential crimp technology. Its compact design (pin length: 1.551 in, body length: 2.377 in, OD: 0.700 in) allows for efficient installation in tight spaces. The connector is distributed by Gross Automation and NSi Industries, with technical support available for crimping tool selection and application guidance.
  • UL486A/B listed for wire connectors; 600V max, 90°C temperature rating
  • Bi-metal design for aluminum (400 kcmil) to copper (250 kcmil) connections
  • Stranded copper pin, tin-plated; PVC insulating cover included
  • Die code 87H (brown color); oxide inhibitor coating for corrosion resistance
  • Compact dimensions: 1.551" pin length, 2.377" body length, 0.700" OD

Specifications

Color
Brown
Finish
Tin-Plated
Finish
Tinned
Housing Material
Aluminum
Housing Material
Aluminium
Material
Aluminum
Special Features
Converts an aluminum cable into a two-sizes-smaller copper pigtail
Standard
UL E63167
Temperature Rating
90 C
Temperature Rating, Maximum
194 F
Temperature Rating, Maximum
90 C
Temperature Rating, Minimum
194 F
Temperature Rating, Minimum
90 C
Type
Bi-Metallic Pin Terminal with Shrink Insulator
Voltage Rating
600 V
Wire Size
250 kcmil
Package Dimensions (L x W x H)
8 IN x 5 IN x 4 IN
Package Dimensions (L x W x H)
20.32 cm x 12.7 cm x 10.16 cm
Package Weight (Imperial)
0.540 L
Package Weight (Metric)
0.245 kg
Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 500 kcmil to Copper Pigtail Wire Size 350 kcmil, Die Code 87H, Die Color Code Brown

61965

Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 500 kcmil to Copper Pigtail Wire Size 350 kcmil, Die Code 87H, Die Color Code Brown
StrongHold Quick Splice, 12 - 10 to 18 - 14 AWG (4 to 0.75-1.5mm2)

EQSP10-18D-Q

StrongHold Quick Splice, 12 - 10 to 18 - 14 AWG (4 to 0.75-1.5mm2)
Lay In Connector 4 - 14 AWG offers the ultimate in flexibility. Excellent for grounding and continuous loop applications. Made of 6061T-6 aluminum alloy. Electro-tin plated for low contact resistance. Suitable for use with both copper and aluminum conductors. Rated 600V (2000V max. per UL486B). UL 486A/B Listed. Temperature rating 90 degrees C.

GLA-4

Lay In Connector 4 - 14 AWG offers the ultimate in flexibility. Excellent for grounding and continuous loop applications. Made of 6061T-6 aluminum alloy. Electro-tin plated for low contact resistance. Suitable for use with both copper and aluminum conductors. Rated 600V (2000V max. per UL486B). UL 486A/B Listed. Temperature rating 90 degrees C.
Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 250 kcmil to Copper Pigtail Wire Size 3/0 AWG, Tin Plated, Die Code 66, Die Color Code White

61950

Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 250 kcmil to Copper Pigtail Wire Size 3/0 AWG, Tin Plated, Die Code 66, Die Color Code White
Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 3/0 AWG to Copper Pigtail Wire Size 1/0 AWG, Tin Plated, Die Code 60, Die Color Code Ruby

61940

Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 3/0 AWG to Copper Pigtail Wire Size 1/0 AWG, Tin Plated, Die Code 60, Die Color Code Ruby
Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 350 kcmil to Copper Pigtail Wire Size 250 kcmil, Die Code 71H, Die Color Code Red

61960

Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 350 kcmil to Copper Pigtail Wire Size 250 kcmil, Die Code 71H, Die Color Code Red
Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 600 kcmil to Copper Pigtail Wire Size 400 kcmil, Die Code 107H, Die Color Code Orange

61970

Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 600 kcmil to Copper Pigtail Wire Size 400 kcmil, Die Code 107H, Die Color Code Orange
Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 6 AWG to Copper Pigtail Wire Size 8 AWG, Tin Plated, Die Code 24, Die Color Code Blue

61910A

Bi-Metal Pin Connectors with Insulating Cover, 600V, Aluminum Cable Size 6 AWG to Copper Pigtail Wire Size 8 AWG, Tin Plated, Die Code 24, Die Color Code Blue

How to Install the Bi-Pin Connector for Aluminum to Copper Cable Transitions

This guide provides step-by-step instructions for installing a Bi-Pin connector to transition from aluminum to copper cables safely and effectively.

Estimated time: 1h

Tools needed:

Screwdriver, Wire strippers, Multimeter, Crimping tool

Supplies needed:

Bi-Pin connectors, Insulators, Aluminum cable, Copper pigtails, Mechanical connectors, Mounting screws

  1. Prepare the aluminum cable

    Strip the aluminum cable to the length specified in the tool die selection table. Clean the cable with a wire brush or emery cloth to ensure a good connection.

  2. Install the Bi-Pin connector

    Insert the stripped aluminum cable fully into the Bi-Pin connector barrel. Use the appropriate color-coded dies to crimp the connector securely, ensuring the die number matches the number embossed on the connector.

  3. Attach the copper pigtail

    Slip the insulator over the copper wire end and pull it over the connector body. Insert the copper pigtail fully into the mechanical connector body and tighten the set screw to the manufacturer's recommended torque.

  4. Verify connections

    Use a multimeter to check the continuity of the connection. Ensure there are no shorts and that the connection is secure before powering the system.

  5. Follow safety precautions

    Always disconnect power before installation. Wear appropriate personal protective equipment, including gloves and safety glasses, to prevent injury.

Frequently Asked Questions about ABB - Installation Products

How are Thomas and Betts products typically installed?

Thomas and Betts products are installed using a variety of methods tailored to specific applications, including the use of flexible cords and cable fittings, non-metallic cable glands, and armored cable fittings. Proper selection of fittings is crucial to match the cable type and installation environment, ensuring durability and preventing physical damage. Tools such as the Blackburn® Comfort Crimp® and HEX-FLEX® systems enhance installation efficiency and reliability, reducing labor time and ensuring secure connections.

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Thomas and Betts offers a comprehensive range of accessories for their products, including various cord and cable fittings, non-metallic cable glands, service entrance cable fittings, and armored cable fittings. Their accessories are designed to enhance installation efficiency and ensure compatibility with different cable types and environmental conditions, providing reliable connections for a wide array of applications.

What environmental ratings do Thomas and Betts products have?

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Thomas and Betts products are known for their innovative designs, high performance, and compliance with industry standards such as the National Electrical Code and Underwriters' Laboratories. They offer a comprehensive range of rugged and reliable electrical fittings, including liquidtight and dust-tight connections, which enhance installation efficiency and reduce overall project costs. Their products are engineered for durability in harsh environments, ensuring long-term reliability and lower installed costs.

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What are the main product lines offered by Ocal?

Ocal offers a comprehensive range of corrosion-resistant conduit systems, including PVC-coated conduit and fittings, conduit bodies, hazardous location fittings, and strut accessories. Their products are designed to provide superior corrosion protection, featuring a hot-dipped galvanizing process and UL listed Type 4X PVC-coated conduit bodies, ensuring durability in the most demanding environments.