Figure 1
Housing Closed Barrel Contact Reducing Bushing
(For Smaller Wire Sizes)
Key (Position
Varies)
Mating
Face
Tab
Contact Cavities
Marking for
Positive Polarity
Marking for
Negative Polarity
Wire
Barrel
Retaining
Spring
Retaining
Spring
Note: Other color codes and voltage ratings are available upon request.
Application Specification
Power Series 50 114--13071
LOC B
1of 9
E2010 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1--800--722--1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
Connector Assemblies 02 FEB 10 Rev B
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_.
Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for application of Power Series 50 connector assemblies in
high--current systems for power supplies, battery chargers, telecommunications, and material handling
equipment. The connector assembly consists of a hermaphroditic housing and two closed barrel contacts.
The contacts are available in sizes 6, 8, and 10--12 and accept wire sizes (AWG) that correspond to the
contact size. Reducing bushings are available for contact size 6 to accommodate smaller wire sizes to a
minimum of size 16 AWG. These contacts feature a flared wire barrel and round--ended tab. The contacts are
available in loose--piece for terminating with manual or pneumatic hand--held tools and in reeled form for
terminating with semi--automatic machines.
The housing features two contact cavities each marked on top of the housing with a plus (+) to indicate positive
polarity and a minus (--) to indicate negative polarity. Each contact is held in the cavity by an internal retaining
spring. The hermaphroditic design of the housing ensures proper polarity in mating of the connectors. In
addition, the housings are color coded to provide visual reference for proper mating and a molded--in
mechanical key at the mating face prevents inadvertent mating of different colored housings (housings with
same position keys will only engage housings of the same color). The housing color is also coded for
recommended application voltage.
When corresponding with personnel, use the terminology provided in this specification to facilitate your
inquiries for information. Basic terms and features of this product are provided in Figure 1.
SYSTEM VOLTAGE (V) RECOMMENDED
HOUSING COLOR
12 Yellow
24 Red
36 Gray
48 Blue
80 Black
NOTE
i
Power Series 50 Connector Assemblies 114- 13071
Rev B2 of 9 Tyco Electronics Corporation
2. REFERENCE MATERIAL
2.1. Revision Summary
SModified pneumatic tooling information in Figure 7
2.2. Customer Assistance
Reference Product Part Number 647845 and Product Code G802 are representative of Power Series 50
connector assemblies. Use of these numbers will identify the product line and expedite your inquiries through a
service network established to help you obtain product and tooling information. Such information can be
obtained through a local Representative or, after purchase, by calling PRODUCT INFORMATION at the
number at the bottom of page 1.
2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technical
documentation supplied, call PRODUCT INFORMATION at the number at the bottom of page 1.
2.4. Instructional Material
Instruction Sheets (408--series) provide assembly instructions and Customer Manuals (409--series) provide
machine setup and operation procedures. Documents available which pertain to this product are:
408--4089 Ratcheted Cable Cutter Hand Tool 607453--2
408--4557 Heavy Duty Cable Cutter Hand Tool 605743--1
408--4559 Heavy Duty Cable Cutter Hand Tool 605744--1
408--4561 Heavy Duty Cable Cutter Hand Tool 600769--1
408--8059 General Preventive Maintenance for Miniature Quick--Change Applicators
408--8540 Crimp Tool 1526955--1
408--8636 Power Series 50 Connector Assemblies
408--9688 Cable Stripper/Slitter Tool 606700--1
408--9816 Handling of Reeled Products
409--1993 AMP--TAPETRONIC* Machine 69875
3. REQUIREMENTS
IMPORTANT: Using the exact products and application requirements described in this document will ensure
proper application; however, to ensure reliability of performance, it is highly recommended that an independent
evaluation be conducted of the chosen product combinations (wire, connector assemblies, and system) before
final application is approved.
3.1. Special Assembly Considerations and Safety
These connectors MUST NOT be used for interrupting current; otherwise, there is risk of electrical shock. In
any case, the electrical power supply must ALWAYS BE DISCONNECTED, and the connectors must ALWAYS
BE DE--ENERGIZED (this might include disconnecting the cable from the battery) before mating and unmating
or servicing the connectors.
It is highly recommended that these connectors not be used in external power applications where the electrical
potential exceeds 42 V. In applications where these connectors are located internal to a device and do not
serve as the primary means of connection, high voltages are allowable. It must be determined by the original
equipment manufacturer (OEM) whether the connectors meet electrical and safety requirements when used in
a specific application.
In applications where the connectors are used external to a device or as the primary means of disconnecting power
supplies or charging equipment, care must be taken to avoid touching exposed electrical contacts as there is risk of
electric shock.
DANGER
Power Series 50 Connector Assemblies 114- 13071
Rev B 3 of 9Tyco Electronics Corporation
3.2. Limitations
This product is designed to operate in a temperature range of --20_to 105_C[--4_to 221_F].
3.3. Material
The housing is made of polycarbonate, rated 94 V--0 by Underwriters Laboratories Inc. (UL). The springs
(inside the housing) are made of stainless steel. The contacts and reducing bushing are made of copper plated
with silver.
3.4. Storage
A. Ultraviolet Light
Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing
material.
B. Shelf Life
The housings and contacts should remain in the shipping containers until ready for use to prevent
deformation. The housings and contacts should be used on a first in, first out basis to avoid storage
contamination that could adversely affect performance.
C. Chemical Exposure
Do not store housings or contacts near any chemical listed below as they may cause discoloration of the
plated finish of the contacts or stress corrosion cracking in the housing or contact material.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
3.5. Wire Selection and Preparation
The contacts accept stranded (recommended a minimum of 19 strands) copper wire sizes 6 through 12 AWG
with a maximum insulation diameter of 11.18 mm [.440 in.]. Contact size 6 can accept smaller wire sizes to a
minimum of size 16 AWG with the use of the appropriate size reducing bushing (as described in
Paragraph 3.6).
Wires with less than 19 strands may be too stiff and difficult to work with.
Tarnished copper wire must be thoroughly cleaned using a stiff wire brush, or other suitable method, that
penetrates the entire bundle and cleans every conductor. The wire must be restored to a bright copper finish.
The contact wire barrels are lined with silver plating to assure consistently high conductivity which will be
reduced if tarnished wire is used.
The wire must be cut to length. Proper strip length is necessary to properly insert the conductors into the
contact. The strip length of the wire is shown in Figure 2.
Reasonable care must be taken not to nick or scrape any part of the wire during the stripping.
12.06--13.33 [.475--.525]
Wire Strip Length
Note: Not to Scale
Figure 2
NOTE
i
CAUTION
!
Power Series 50 Connector Assemblies 114- 13071
Rev B4 of 9 Tyco Electronics Corporation
3.6. Reducing Bushing
Reducing bushings are available for contact size 6 to accommodate smaller wire sizes to a minimum of size
16 AWG. When required, the appropriate size reducing bushing must be installed onto the wire before inserting
the wire into the contact (the reducing bushing can be installed onto the wire before or after stripping the wire).
Placement of the reducing bushing must meet the requirements shown in Figure 3.
Figure 3
Ends of Conductors
Must Be Visible
1.52 [.060] Max
Reducing Bushing to Wire Insulation
Placement of Reducing Bushing on Stripped Wire
Placement of Wire and Reducing Bushing in Contact
0.38 [.015] Max
Reducing Bushing Protrudes from Contact
Wire and Reducing Bushing
Must Be Straight in Relation
to Contact Wire Barrel
Contact Size 6
Wire Insulation Must Not Enter Reducing Bushing
3.7. Crimp Requirements
A. Reducing Bushing
If a reducing bushing is used, the reducing bushing must be held firmly inside the contact wire barrel. The
reducing bushing must be straight in relation to the wire barrel and can protrude from the wire barrel to the
dimension provided in Figure 4.
B. Tab
The contact tab must not be deformed in any way. See Figure 4.
C. Wire Barrel Crimp
All conductors must be held firmly inside the wire barrel. The crimp applied to the contact wire barrel is the
most compressed area and most critical in ensuring optimum performance of the crimped contact. The
crimped area must be symmetrical on both sides of the wire barrel as shown in Figure 4.
The developed crimp configurations result from using the specific tooling described in Section 5, TOOLING.
D. Wire Conductor and Insulation Location
No conductors can be folded back over the wire insulation. The insulation must not enter the wire barrel.
The conductors must be visible between the reducing bushing, if applicable, or contact wire barrel and the
wire insulation within the dimension stated in Figure 4.
NOTE
i
Power Series 50 Connector Assemblies 114- 13071
Rev B 5 of 9Tyco Electronics Corporation
A
A
Detail A-A
Wire Insulation Does Not
Enter Contact Wire Barrel
No Loose Conductors or Conductors
Folded Over Wire Insulation
1.59 [.062] Max
Conductor Visible
Crimp Requirements
0.38 [.015] Max
Reducing Bushing (If Applicable)
Protrudes from Wire Barrel
Crimped Area Symmetrical on
Both Sides of Wire Barrel
Tab Not Deformed
in Any Way
Dual--Indent CrimpSingle--Indent Crimp
Figure 4
Note: Dual--indent crimp shown. Requirements apply equally to single--indent crimp.
Most Compressed Area
of Wire Barrel
Most Compressed Area
of Wire Barrel
E. Twist and Roll
There should be no twist or roll of the wire barrel of the crimped contact that would cause overstress or
impair usage. See Figure 5.
Figure 5
Uncrimped Portion
Crimped Portion
Avoid Twist
and Roll
Datum Line
Power Series 50 Connector Assemblies 114- 13071
Rev B6 of 9 Tyco Electronics Corporation
F. Bend Allowance
The force applied during crimping may cause some bending between the wire barrel and wire. Such
deformation is acceptable within the following limits.
1. Up and Down
The crimped portion must not be bent beyond the limits shown in Figure 6.
2. Side--to--Side
The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 6.
Figure 6
Up and Down Alignment
Side-to-Side Alignment
Datum Line
Datum Line
2_
2_
2_
2_
Note: Dual--indent crimp shown. Requirements apply equally to single--indent crimp.
3.8. Keying
Assurance of proper mating is provided by a molded--in mechanical key at the mating face of the housing. The
position of the key of the mating housings must be compatible. The customer drawing for the specific housing
provides the key position.
Other key positions are available upon request.
3.9. Installing Contacts into Housing
The electrical supply MUST BE DISCONNECTED and the connectors MUST BE DE--ENERGIZED (this might include
disconnecting the cable from the battery) before installing the contacts into the housing.
The contacts must NOT be forced into the housing. Each contact must be installed in the housing according to
the following requirements.
1. Each contact must be inserted into the wire side of the housing.
2. The bottom of each contact must face the retention spring of the housing.
3. Each contact must be in straight alignment with the contact cavity.
4. Each contact must be fully latched onto the housing retaining spring.
NOTE
i
DANGER
Power Series 50 Connector Assemblies 114- 13071
Rev B 7 of 9Tyco Electronics Corporation
3.10. Removing Contacts from Housing
The housing retention spring must be depressed away from the underside of the contact to remove the contact
from the housing. A contact must be removed from the housing according to the following:
The electrical supply MUST BE DISCONNECTED and the connectors MUST BE DE--ENERGIZED (this might include
disconnecting the cable from the battery) before removing the contacts from the housing.
Section 5 lists available extraction tools used to remove these contacts.
1. The tip of the tool must be inserted between the sides of contact and the contact cavity at the mating
face of the housing.
2. The handle of the tool must be pushed down so that the housing retention spring is depressed away
from the underside of the contact. While holding the tool in position, the wire must be pushed down and
gently pulled back until the contact is free from the housing.
3.11. Mating and Unmating Connectors
The electrical supply MUST BE DISCONNECTED and the connectors MUST BE DE--ENERGIZED (this might include
disconnecting the cable from the battery) before mating or unmating the connectors.
The connectors must NOT be forced to mate or unmate. When fully mated, the housings must appear flush at
the point of engagement.
3.12. Repair
The contact, housing, and reducing busing are not repairable. Damaged or defective contacts, housings, or
reducing bushings must not be used. The contacts or reducing bushings must not be re--used by removing the
wire.
4. QUALIFICATION
Power Series 50 connector assemblies are Component Recognized by Underwriters Laboratories Inc. (UL) in
File E28476 and have been Investigated to CSA International Standards by UL.
5. TOOLING
Tooling part numbers and instructional material packaged with the tooling are shown in Figure 7.
5.1. Cable Cutters
These cable cutters are available for cutting the cable to length.
5.2. Hand Tools
Hand tools for manual application of loose piece contacts are available to cover the full wire size range.
Industry standard tooling for manual application of loose piece contacts is available for the full wire size range.
Recommended manufacturer and tooling description and part numbers are given in Figure 7.
Consult manufacturer’s literature for information on using the tooling.
5.3. Power Unit
A semi--automatic machine for power assisted application of tape and reeled contacts are available for the full
wire size range. The machine is designed to be used as stand--alone bench unit.
DANGER
NOTE
i
DANGER
NOTE
i
Power Series 50 Connector Assemblies 114- 13071
Rev B8 of 9 Tyco Electronics Corporation
5.4. Extraction Tool
The extraction tool or a standard insulated screwdriver with 1/4--in. flat blade must be used to remove contacts
from the housing.
5.5. Stripping Tool
The cable stripper is used to strip insulation from the cable.
Standard Insulated Screwdriver
With 1/4--in. Flat Blade
AMP--TAPETRONIC Machine
69875 (409--1993)
Extraction Tool 68265--1
(No Document)
Crimp Tool 1526955--1
(408--8540)
Heavy Duty Cable Cutter Hand Tool
600769--1 (408--4561)
Heavy Duty Cable Cutter Hand Tool
605743--1 (408--4557)
Heavy Duty Cable Cutter Hand Tool
605744--1 (408--4559)
Ratcheted Cable Cutter Hand Tool
607453--2 (408--4089)
Cable Stripper/Slitter Tool
606700--1 (408--9688)
Commercially Available Pneumatic Hand Crimping Tool,
Die Set, and Locator (Dual--Indent Crimp)
Available from Pacific Industrial Components (PICO)
Camarillo, CA (805) 388--5510
(http://www.picotools.com)
(See Table)
SERIES DIE SET LOCATOR
DIE CLOSURE FOR
CONTACT SIZE
S
E
R
I
E
S
D
I
E
S
E
T
L
O
C
A
T
O
R
6and8 10--12
4
0
0
414DA--4583
4
5
8
2
1
400 414DA--4582 4582--1
1
5
2
i
n
1
3
4
i
n
5
0
0
514DA--7033
7
0
3
3
1
.152 in. .134 in.
500 514DA--7034 7033--1
Figure 7
Power Series 50 Connector Assemblies 114- 13071
Rev B 9 of 9Tyco Electronics Corporation
6. VISUAL AID
Figure 8 shows a typical application of Power Series 50 connector assemblies. This illustration should be used
by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct
should be inspected using the information in the preceding pages of this specification and in the instructional
material shipped with the product or tooling.
FIGURE 8. VISUAL AID
WIRE INSULATION MUST
NOT ENTER CONTACT
WIRE BARREL
CONTACTS MUST BE
SECURE IN HOUSINGS
THERE MUST BE
NO DAMAGE TO
CONNECTORS
CONTACT MUST BE
STRAIGHT AND NOT
DAMAGED IN ANY WAY
WIRE INSULATION MUST
NOT BE CUT OR BROKEN
REDUCING BUSHING (IF
APPLICABLE) MUST BE FLUSH
WITH, OR PROTRUDE SLIGHTLY
FROM, CONTACT WIRE BARREL
CONNECTORS MUST BE
FULLY MATED (HOUSINGS
APPEAR FLUSH AT POINT
OF ENGAGEMENT)
CONDUCTORS MUST BE VISIBLE BETWEEN
REDUCING BUSHING (IF APPLICABLE) OR
CONTACT WIRE BARREL AND WIRE INSULATION
THEREMUSTBENOLOOSE
CONDUCTORS OR CONDUCTORS
FOLDED OVER WIRE INSULATION
CRIMPED AREA MUST BE
SYMMETRICAL ON BOTH
SIDES OF WIRE BARREL
DUAL- INDENT CRIMP
SINGLE- INDENT CRIMP