Power Connectors for Industrial and Commercial Applications Table of Contents AMP Power Series Connectors Selection Guide and Overview...........................................................................3,4 Series 15/30/45 (Single-Pole)..............................................................................5 Series 50 (2-Pole Battery) .................................................................................6 Series 50 Finger Probe Resistant (FPR)..................................................................7 Series 75 (Single-Pole) ....................................................................................8 Series 120 (Single-Pole) .................................................................................9 Series 120 (2-Pole Battery) ..............................................................................10 Series 175 (2-Pole Battery) ..............................................................................11 Series 180 (Single-Pole) .................................................................................12 Series 350 (2-Pole Battery) ..............................................................................13 Accessories .............................................................................................14,15 Application Tooling ....................................................................................16,17 AMPINNERGY Connectors Wire-To-Wire Introduction and Technical Documents ............................................................18 1-Pole Housing and Accessories ..................................................................19 Contacts and Application Tooling ..................................................................20 Wire-To-Board Introduction and Technical Documents ............................................................21 PC Board Receptacles..............................................................................22,23 Plug Housings (2- to 8-Position) .....................................................................24 Contacts and Application Tooling ..................................................................25 Technical Documents ..........................................................................................26 Part Number Index .............................................................................................27 Related Product Catalogs .................................................................................28,29 Engineering Notes .............................................................................................30 AMP, AMPINNERGY, AMPOWER, AMP-O-LECTRIC, AMP-TAPETRONIC, DIAMOND GRIP, ELCON, RAYCHEM, SOLISTRAND, and TYCO are trademarks. Global Contacts ................................................................................................31 PICO is a trademark of Pacific Industrial Components Corporation. Other products, logos, and company names mentioned herein may be trademarks of their respective owners. (c) 2005 by Tyco Electronics Corporation. All Rights Reserved. While Tyco Electronics has made every reasonable effort to ensure the accuracy of the information in this catalog, Tyco Electronics does not guarantee that it is error-free, nor does Tyco Electronics make any other representation, warranty or guarantee that the information is accurate, correct, reliable or current. Tyco Electronics reserves the right to make any adjustments to the information contained herein at any time without notice. Tyco Electronics expressly disclaims all implied warranties regarding the information contained herein, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. The dimensions in this catalog are for reference purposes only and are subject to change without notice. Specifications are subject to change without notice. Consult Tyco Electronics for the latest dimensions and design specifications. 2 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series Connectors Product Facts n Single-pole and 2-pole (battery) quick connect/disconnect connectors n Eight Series, based on approximate currentcarrying capability: n Series 15/30/45 (Single-Pole) n Series 50 (2-Pole Battery) n Series 50 Finger Probe Resistant (FPR) n Series 75 (Single-Pole) n Series 120 (Single- and 2-Pole) n Series 175 (2-Pole Battery) n Series 180 (Single-Pole) n Series 350 (2-Pole Battery) n Voltage rating: 600 V AC/DC n Color-coded housings, UL 94V-0 n Hermaphroditic (genderless) housings reduce inventory n Modular, single-pole housings are stackable in four directions n Polarity (+ and -) molded into 2-pole housings promotes proper wiring n Mechanical keys help prevent two different colorcoded housings from mating n Stainless steel retaining springs secure contacts in housings n Stamped and formed, open barrel contacts (6-20 AWG) on reels for automatic and semiautomatic machine termination n Loose piece, cold-headed contacts (6 AWG - 300 MCM) for manual and hydraulic hand tools; reducing bushings accommodate smaller wire sizes n Compatible with industry standard crimp tooling from PICO Corporation (http://www.picotools.com) n Connectors intermateable with similar connectors from other manufacturers n Series 15/30/45, single-pole connectors designed to meet Amateur Radio Emergency Service (ARES)/Radio Amateur Civil Emergency Service (RACES) Standard Power Connector requirements n Accessories available for mounting, vibration protection, and strain relief n Component Recognized by Underwriters Laboratories Inc. to US and Canadian Standards, File No. E28476 (R) C US AMP Power Series Connectors provide a durable, quick connect/disconnect means to transmit "power" levels of current and voltage (15-275 A, 600 V AC/DC). This product family is primarily comprised of single-pole and 2-pole (battery) connector housings, crimp snap-in contacts, and accessories. Housings are offered in various colors. Two-pole housings have different polarization configurations; with the exception of black housings, each color identifies a different keying configuration. In general, only like color housings will mate. Contacts are either cold-headed or stamped and formed, depending upon the connector Series. AMP Power Series Connectors are divided into eight Series, based on approximate current-carrying capability. Applications AC/DC Power Supplies and Charging Systems, Rechargeable Batteries, Material Handling Equipment (e.g. forklift trucks), Electric Vehicles (e.g., golf carts, sweepers, wheelchairs), Office Furniture/Panels, Amateur Emergency Radios, and Industrial Equipment Technical Documents See page 26 3 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series Connectors (Continued) AMP Power Series 15/30/45 AMP Power Series 120 Single-pole connector housings are stackable side-to-side and top-to-bottom. For example, Series 30 red and black housings joined side-to-side, are commonly used as standard power connectors for handheld, mobile, or base amateur radio equipment. This Series includes both singleand 2-pole (battery) versions. Single-pole housings with molded-in dovetails allow stacking. Housing retaining pins provide more vibration protection. Two-pole housing have slots designed to accept mounting clamp sets for easier panel mounting. Modular housings can also be grouped into plug frames with or without latches, which mate with receptacle housings. Typically, these are used as quick disconnects for electrical power distribution in office furniture and panels. AMP Power Series 175 Two-pole (battery) housings accept coldheaded contacts (4-1/0 AWG). Basically, these connectors offer the same features as the two-pole Series 50 connectors. AMP Power Series 50 Two-pole (battery) housings are available in bulk quantities or in kit form (i.e., 1 housing and 2 contacts). These high durability connectors are designed for repeated mating and unmating. AMP Power Series 180 These stackable, single-pole connectors accept cold-headed contacts (4-1/0 AWG). Most features are similar to the smaller, single-pole, Series 120 connectors. AMP Power Series 50 Finger Probe Resistant (FPR) AMP Power Series 350 This new, 2-pole, FPR version helps prevent finger access, which allows it to be more safely used at elevated voltages and in user access areas. Rugged, 2-pole housings accept only loose piece, cold-headed contacts (1/0-300 MCM). Rated at 275 A, these connectors have been tested up to 275 A, with 4/0 AWG wire. AMP Power Series 75 Single-pole, stackable housings, in locking and non-locking versions, are available in a variety of colors. Housings accept stamped and formed or cold-headed contacts. Bulk quantities and connector kits (1 housing and 1 contact) can be ordered. Accessories include: mounting wings for through-panel or surface mounting and mounting clamp sets for ganging housings. Selection Guide Series Housing Type Stackable Housing 15 Single-Pole Yes 30 45 50 75 120 120 175 180 350 4 Single-Pole Single-Pole 2-Pole Single-Pole Single-Pole 2-Pole 2-Pole Single-Pole 2-Pole Yes Yes No Yes Yes No No Yes No Current Voltage, Max. Max. (A) (V, AC or DC) 15 30 40* 50 75 120 120 175 180 275** 600 600 600 600 600 600 600 600 Cold-headed Contact (AWG) Stamped & Formed Contact (AWG) -- 16-20 -- -- 6, 8, 10-12 6, 8,10-12 2, 4, 6 2, 4, 6 1/0, 1, 2, 4 600 1/0, 1, 2, 4 600 1/0, 2/0, 3/0, 4/0, 300 MCM 12-16 10-14 6-10,10-12 6-10,10-12 -- Housing Colors Approvals Blue, Black, White, Red Green, Yellow, Orange, Gray Blue, Black, White, Red Green, Yellow, Orange, Gray Blue, Black, White, Red Green, Yellow, Orange, Gray Red, Gray, Blue, Black, Yellow Blue, Black, White, Green, Red (Single-Pole) Blue, Black, White, Green, Red (Single-Pole) -- Blue, Gray (2-Pole) -- Blue, Gray, Orange, Yellow, Red Blue, Black, White, Green, Red Blue, Green, Red, Yellow, Orange, Gray -- -- (R) C US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 US File No. E28476 (R) C (R) C (R) C (R) C (R) C (R) C (R) C (R) C (R) C *Performance equivalent to competition **Tested to 275 amps with 4/0 AWG wire Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 15/30/45 Connectors (Single-Pole) Product Facts .141 004 [ 3.58 0.1] Stamped and Formed Contact (Strip) Single-Pole Housing n Color-coded UL 94V-0 .141 004 [ 3.58 0.1] R .051 [1.3] .331 [8.4] .968 [24.6] Dovetails allow stacking in vertical, horizontal, or in block configurations. .390 [9.9] When mated side-to-side, half rounds align to form a slot for roll pin insertion which protects against accidental dislodging of mated housing. .311 [7.9] .311 [7.9] housings: blue, black, white, .390 green, red, yellow, orange [9.9] and gray .311 n Genderless housings reduce [7.9] R .051 inventory When mated side-to-side, [1.3] half rounds align to form n 3 contact offerings available: a slot for roll pin insertion .311 Series 15, 30 and 45 which protects against [7.9] accidental dislodging of Closed Barrel Contact (Loose Piece) mated housing. n Built-in interlocking features (dovetails) allow stacking Dovetails allow stacking in vertical, .150 n Series 15/30/45, single-pole horizontal, or in block configurations. [3.81] connectors designed.390to meet .968 [9.9] [24.6] Amateur Radio Emergency .630 Service (ARES)/Radio [16.00] .311 [7.9] Amateur Civil Emergency .331 R .051 [8.4] Service (RACES) Standard When mated side-to-side, [1.3] rounds align to form Power Connector half a slot for roll pin insertion .311 which protects against requirements [7.9] accidental dislodging of housing. n Plug frames (with ormated without .275 .290 [6.99] [7.36] latches) and receptacle AMP Power Series 15 Dovetails allow stacking in vertical, housings accept stacked horizontal, or in block configurations. Housing1 Contact Part Number single-pole housings (2 to .968 Loose Piece [24.6] Color 8 poles) Part Number Strip Form (16, 18, 20 AWG) (16-20 AWG) US n File No. E28476 C Blue 1445957-1 .152 Dia. [3.86] (R) .331 Black White Green Red Yellow Orange Gray [8.4] Material and Finish Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver or tin plating Mounting Wings & Spacers-- Polycarbonate, UL 94V-0 Retaining Pins--Stainless steel 1445957-2 1445957-3 1445957-4 1445957-5 1445957-6 1445957-7 1445957-8 1604113-1 (silver)2 1604113-2 (tin)2 AMP Power Series 30 Housing1 Electrical Characteristics Current Carrying Capability-- 40 A w/10 AWG wire (Series 45) 30 A w/12 AWG wire (Series 30) 20 A w/16 AWG wire (Series 15) Operating Voltage--600 V, AC or DC Dielectric Withstanding Voltage-- 2200 VDC Average Initial Contact Resistance--525 micro-ohms 1744042-1 Contact Part Number Color Part Number Strip Form (12, 14, 16 AWG) Blue Black White Green Red Yellow Orange Gray 1445957-1 1445957-2 1445957-3 1445957-4 1445957-5 1445957-6 1445957-7 1445957-8 1604112-1 (silver)3 1604112-2 (tin)3 Loose Piece (12-16 AWG) 1744041-1 Dimensions shown above. AMP Power Series 45 Housing1 Color Blue Black White Green Red Yellow Orange Gray Mechanical Characteristics Contact Retention--25 lbs. [111.2 N] Average Mating/Unmating Force--4.7 [20.9 N] Max. Wire Insulation Diameter-- 175 [18.16] Wire Size Range--10-20 AWG [5-0.5 mm2] 1 2 Contact Part Number Strip Form (10, 12, 14 AWG) Part Number 1445957-1 1445957-2 1445957-3 1445957-4 1445957-5 1445957-6 1445957-7 1445957-8 Housings are bulk packaged. Use Applicator Part No. 1385450-3 1445962-1 (silver)4 1445962-2 (tin)4 3 4 Use Applicator Part No. 1385468-3 Use Applicator Part No. 1385469-3 Related Product Data Accessories--page 14 Note: Tyco Electronics does NOT recommend intermating connectors with different contact platings. 5 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 50 Connectors (2-Pole Battery) Cold-headed Contact 2-Pole Housing Product Facts n Color-coded UL 94V-0 housings: gray, red, blue, yellow and black; other colors available upon request Note: Black color housing has the same mechanical key as the gray housing n Mechanical keys help prevent two different voltage color- coded housings from mating n Polarity (+ and -) molded into housings n Genderless housings reduce inventory n Cold-headed contact wire range: 6, 8, 10-12 AWG (Taped version of the cold-headed contacts available.) US n File No. E28476 C (R) 1.38 [35.05] .290 [7.37] Ref. .50 [12.7] .323 [8.2] 1.90 [48.23] * Stamped and Formed Contact (on Reel) .625 [15.88] 1.28 [32.64] Series 50 (2-Pole) Material and Finish Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Reducing Bushings--Copper with silver plating Contact Retention--50 lbs. [222.4 N] Average Mating/Unmating Force-- 15 lbs. [66.7 N] Max. Wire Insulation Diameter-- .44 [11.18] Wire Size Range--6-12 AWG (also 6-16 AWG w/Reducing Bushings) Contact2 Color Part Number Red 647845-3 Gray 647845-4 Blue 647845-5 Black4 647845-7 Yellow 647845-8 Cold-headed Contact 5Stamped and Formed contacts, on Reel 6Stamped and Formed contacts, on Reel Electrical Characteristics Mechanical Characteristics *Inside Diameter 6 AWG .222 [5.64] 8 AWG .187 [4.75] 10-12 AWG .150 [3.81] Housing2,3 Current Carrying Capability-- 50 amp per circuit w/6 AWG wire Max. Operating Voltage--600 V, AC or DC Dielectric Withstanding Voltage-- 2200 VDC Average Initial Contact Resistance--200 micro-ohms 1.23 [31.2] 7Taped version of Cold-headed contacts Wire Size 6 AWG 10-12 AWG 6 AWG 10-12 AWG 6 AWG 10-12 AWG 6 AWG 10-12 AWG 6 AWG 10-12 AWG 8 AWG 6-8 AWG 10-12 AWG 6 AWG 8 AWG 10-12 AWG Connector Kit Part Number1 Part Number 647877-1 647892-3 647879-1 647893-3 647877-1 647892-4 647879-1 647893-4 647877-1 647892-5 647879-1 647893-5 647877-1 647892-7 647879-1 647893-7 647877-1 647892-8 647879-1 647893-8 647878-1 -- 1604433-1 strip (tin)8 1604433-2 (strip)8 647754-1 647755-1 647756-1 1 Housing and 2 contacts. Housings and contacts are bulk packaged. Mechanical keys molded in housings will engage only with housings of same color. 4 Black color housing has the same mechanical key as the gray housing. 5 Use Heavy Duty Mini-Applicator (HDM) for 6 to 8 AWG - Part Number 1385663-2 (Use with AMP-O-LECTRIC Model K Terminator) 6 Use Heavy Duty Mini-Applicator (HDM) for 10 to 12 AWG - Part Number 1385664-2 (Use with AMP-O-LECTRIC Model K Terminator) 7 Hand Tool for Cold-headed Contact - Part Number 1526955-1 Taped version can be terminated using the AMP-TAPETRONIC Machine 8 Use Power Lock Machine Part Number 68296-1 1 2 3 Voltage Key Color Chart Related Product Data Accessories--page 14 Housing Color Voltage Yellow Red Gray Blue Black 12V 24V 36V 48V 80V Color code given for various voltages is only a suggestion, other codes and keys available upon request. 6 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 50 FPR (Finger Probe Resistant) Connectors Product Facts Cold-headed Contact 2-Pole Housing n Complies with UL 60950 finger probe requirements n Utilizes AMP Power Series 50 contacts n Brown and white housing colors available (other colors possible) n Two keying configurations available (up to 6 keying configurations possible) US n File No. E28476 C .290 [7.37] Ref. .50 [12.7] .323 [8.2] 1.23 [31.2] *Inside Diameter 6 AWG .222 [5.64] 8 AWG .187 [4.75] 10-12 AWG .150 [3.81] * (R) Stamped and Formed Contact (on Reel) .672 [17.08] 1.28 [32.64] .672 [17.08] Material and Finish Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper Reducing Bushings--Copper with silver plating Series 50 FPR (2-Pole) Housing1,2 Electrical Characteristics Current Capability--50 A max. Voltage Rating--600 V, AC or DC Dielectric Withstanding Voltage-- 2200 VDC Mechanical Characteristics Designed to defeat UL finger probe as outlined in UL 60950 Contact Retention--50 lbs. [222.4 N] Wire Size--6-12 AWG [15-3 mm2] Max. Wire Insulation Diameter-- .44 [11.18] Color Wire Size Part Number Brown 1604342-1 White 1604342-2 6 AWG 8 AWG 10-12 AWG Contact Part Number1 Cold-headed5 Stamped and Formed/Strip3,4,6 Loose Piece 647877-1 647878-1 647879-1 On Tape 647754-1 647755-1 647756-1 On Reel 6-8 AWG 1604433-16 (tin) 10-12 AWG 1604433-26 Housings and contacts are bulk packaged. 2 Mechanical keys molded in housings will engage only with housings of same color. 3 Use Heavy Duty Mini-Applicator (HDM) for 6 to 8 AWG - Part Number 1385663-2 (Use with AMP-O-LECTRIC Model K Terminator) 4 Use Heavy Duty Mini-Applicator (HDM) for 10 to 12 AWG - Part Number 1385664-2 (Use with AMP-O-LECTRIC Model K Terminator) 5 Hand Tool for Cold-headed Contact - Part Number 1526955-1 Taped version can be terminated using the AMP-TAPETRONIC Machine 6 Use Power Lock Machine Part Number 68296-1 1 Related Product Data Accessories--page 14 Applications n Uninterruptible Power Supplies Power Supplies n Battery Banks n 7 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 75 Connectors (Single-Pole) Housing without Locking Feature Product Facts n Color-coded UL 94V-0 housings: blue, black, white, green and red n Genderless housings reduce inventory n Cold-headed contact wire range: 6, 8, 10-12 AWG n Stamped and formed contacts available: 6-8 AWG Part Number 1604433-1 (strip); 10-12 AWG Part Number 1604433-2 (strip) US n File No. E28476 C Housing with Locking Feature Housing/Spring Subassembly Housing/Spring Subassembly Contact Contact Stamped and Formed Contact (on Reel) Cold-headed Contact (R) .290 [7.37] Ref. .50 [12.7] Material and Finish .323 [8.2] Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Reducing Bushings--Copper with silver plating Mounting Wings--Polycarbonate, UL 94V-0 Retaining Pins--Stainless steel *Inside Diameter Series 75 (Single-Pole) Housing2 Color Part Number Cold-headed Contact2 Wire Size Part Number Connector Kit Part Number1 Non-Locking Version Blue Black White Green Red 1445715-1 1445715-2 1445715-3 1445715-4 1445715-5 6 AWG 6 AWG 6 AWG 6 AWG 6 AWG 647877-1 647877-1 647877-1 647877-1 647877-1 1445716-1 1445716-2 1445716-3 1445716-4 1445716-5 1445715-6 1445715-7 1445715-8 1445715-9 1-1445715-0 6 AWG 6 AWG 6 AWG 6 AWG 6 AWG 647877-1 647877-1 647877-1 647877-1 647877-1 1445716-6 1445716-7 1445716-8 1445716-9 1-1445716-0 Locking Version Blue Black White Green Red *Samples available on loose housing and contacts only. Contacts Description Wire Size Part Number Die Set Part Number3 Cold-headed (Loose Piece)4 6 AWG 8 AWG 10-12 AWG Cold-headed (Tape)3, 4 6 AWG 8 AWG 10-12 AWG Stamped and Formed (Strip) 6-8 AWG 10-12 AWG 647877-1 647878-1 647879-1 647754-1 647755-1 647756-1 1604433-1 1604433-2 -- -- -- 68344-1 68344-1 68313-1 -- -- Mechanical Characteristics Contact Retention--50 lbs. [222.4 N] Average Mating/Unmating Force--15 lbs. [66.7 N] Max. Wire Insulation Diameter-- .44 [11.18] Wire Size Range--6-12 AWG [15-3 mm2] * 6 AWG .222 [5.64] 8 AWG .187 [4.75] 10-12 AWG .150 [3.81] Electrical Characteristics Current Carrying Capability (with 6 AWG)--Configuration: Single-Pole 75 A 1x2 Stacked 62 A 2x2 Stacked 60 A 1x3 Stacked 58 A 2x3 Stacked 52 A Operating Voltage--600 V, AC or DC Dielectric Withstanding Voltage-- 2200 VDC Average Initial Contact Resistance--200 micro-ohms 1.28 [32.64] 1.23 [31.2] Applicator Part No. for AMP-O-LECTRIC Model K Terminator -- -- -- -- -- -- 1385663-2 1385664-2 1 housing and 1 contact Housings and contacts are bulk packaged. version can be terminated using the AMP-TAPETRONIC machine Part Number 68250-1. 4 Use hand tool Part Number 1526955-1 for Cold-headed contacts 1 2 3 Taped Related Product Data Accessories--page 14 Application Tooling--page 16 8 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 120 Connectors (Single-Pole) Single-Pole Housing Cold-headed Contact .415 [10.5] 1.059 [26.89] Product Facts n Color-coded modular housings: blue, black, white, green and red n Genderless housings reduce inventory n Cold-headed contact wire range: 2, 4, and 6 AWG n Built-in interlocking features (dovetails) allow stacking and wire routing n Self-wiping contacts increase product life and improve conductivity n Integral stainless steel locking spring in housing for contact retention n Rugged design US n File No. E28476 C 1.99 [50.5] .921 [23.4] .883 [22.42] .883 [22.42] .480 [12.2] * *Inside Diameter 6 AWG .222 [5.64]; 4 AWG .295 [7.5]; 2 AWG .344 [8.74] Series 120 (Single-Pole) Housing Color Blue Black White Green Red -- -- (R) Material and Finish Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Reducing Bushings--Copper with silver plating Mounting Clamp Sets--Aluminum 2.746 [69.74] .094 [2.4] 1 Contact Part Number 1604001-1 1604001-2 1604001-3 1604001-4 1604001-5 -- -- Wire Size 2 AWG 2 AWG 2 AWG 2 AWG 2 AWG 4 AWG 6 AWG Part Number 1445995-1 1445995-1 1445995-1 1445995-1 1445995-1 1445996-1 1445997-1 Connector Kit Part Number1 1604002-1 1604002-2 1604002-3 1604002-4 1604002-5 -- -- 1 Housing and 1 contact. Electrical Characteristics Related Product Data Current Carrying Capability-- Single-Pole--120 A 2x1 Stacked Array--115 A 2x2 Stacked Array--115 A Voltage Rating--600 V (both AC and DC) Dielectric Withstanding Voltage-- 2200 VDC Average Initial Contact Resistance--136 micro-ohms Accessories--page 15 Application Tooling--page 16 Technical Documents--page 26 Mechanical Characteristics Contact Retention--100 lbs. [444.8 N] Average Mating/Unmating Force--8 lbs. [35.6 N] Temperature Rating-- -4F to 221F [-20C to 105C] Max. Wire Insulation Diameter-- .6 [15.24] Wire Size Range--2-6 AWG 9 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 120 Connectors (2-Pole Battery) 2-Pole Housing Cold-headed Contact 1.74 [44.31] .415 [10.5] Product Facts n Color-coded UL 94V-0 housings: gray and blue n Keying feature helps prevent two different voltage color-coded housings from mating n Genderless housings reduce inventory n Contact wire range: 2, 4, 6 and 8 AWG n Molded-in panel mount grooves n Integral stainless steel locking spring in housing for contact retention n Rugged design US n File No. E28476 C 2.50 [63.45] Panel Mount Grooves 2 Plc. .811 [20.6] .480 [12.2] * *Inside Diameter 6 AWG .222 [5.64]; 4 AWG .295 [7.5]; 2 AWG .344 [8.74] Series 120 (2-Pole) Color Gray Blue Gray Blue Gray Blue (R) Material and Finish Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Reducing Bushings--Copper with silver plating 1.99 [50.5] .921 [23.4] Housing2,3 Part Number 1445994-1 1445994-2 1445994-1 1445994-2 1445994-1 1445994-2 Contact2 Wire Size 2 AWG 2 AWG 4 AWG 4 AWG 6 AWG 6 AWG Part Number 1445995-1 1445995-1 1445996-1 1445996-1 1445997-1 1445997-1 Connector Kit Part Number1 1445998-1 1445998-2 1445999-1 1445999-2 1446000-1 1446000-2 1 Housing and 2 contacts. Housings and contacts are bulk packaged. 3 Mechanical keys molded in connectors will engage only with connectors of same color. 1 2 Electrical Characteristics Current Carrying Capability-- 115 A with 2 AWG Voltage Rating--600 V (both AC and DC) Dielectric Withstanding Voltage-- 2200 VDC Avg. Initial Contact Resistance-- 136 micro-ohms Voltage Key Color Chart Housing2,3 Color Gray Blue Voltage 36 V 48 V Color code given for various voltages is only a suggestion, other codes and keys available upon request. Mechanical Characteristics Contact Retention--100 lbs. [444.8 N] Average Mating/Unmating Force--18 lbs. [80.1 N] Temperature Rating-- -4F to 221F [-20C to 105C] Max. Wire Insulation Diameter-- .6 [15.24] Wire Size Range--2-8 AWG Related Product Data Accessories--page 15 Application Tooling--page 16 Technical Documents--page 26 10 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 175 Connectors (2-Pole Battery) Cold-headed Contact 2-Pole Housing Product Facts n Color-coded UL 94V-0 housings: yellow, orange, red, gray, blue, and black n Keying feature helps prevent two different voltage color-coded housings from mating n Genderless housings reduce inventory n Contact wire range: 1/0, 1, 2, 4 AWG n Integral stainless steel locking spring in housing for contact retention n Reducing bushings down to 10 gauge US n File No. E28476 C .5.016 [12.70.4] TYCO 2.35 .03 [59.80.8] Dia. 3.08 [78.2] Inside Diameter .516.005 [13.10.13] for 1/0 AWG .512.005 [13.00.13] for 1 AWG, 2 AWG, and 4 AWG 2.11 [53.5] 1.0 [25.4] (R) Material and Finish Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Reducing Bushings--Copper with silver plating Series 175 (2-Pole) Color Yellow Orange Red Gray Blue Black3 Electrical Characteristics Current Carrying Capability-- 175 amp @ 80.42F [26.9C] T-Rise with 1/0 AWG wire Voltage Rating--600 V (both AC and DC) Dielectric Withstanding Voltage-- 2200 VDC Avg. Initial Contact Resistance-- 100 micro-ohms 1 2 3 Housing Part Number 1604037-1 1604037-2 1604037-3 1604037-4 1604037-5 1604037-6 4 AWG 1604044-1 1604044-2 1604044-3 1604044-4 1604044-5 1604044-6 Connector Kit Part Numbers1, 2 2 AWG 1 AWG 1604043-1 1604045-1 1604043-2 1604045-2 1604043-3 1604045-3 1604043-4 1604045-4 1604043-5 1604045-5 1604043-6 1604045-6 1/0 AWG 1604042-1 1604042-2 1604042-3 1604042-4 1604042-5 1604042-6 1 Housing and 2 contacts. Housings and contacts are bulk packaged. Black housing mates with any other housing. Contacts (Cold-headed) Wire Size 4 AWG 2 AWG 1 AWG 1/0 AWG Mechanical Characteristics Average Mating/Unmating Force--25 lbs. [111.21 N] Max. Wire Insulation Diameter-- .750 [19.05] Wire Size Range--1/0, 1, 2, 4 AWG [53, 40, 35, 21 mm2] Contact Retention--300 lbs. [1,334.47 N] Temperature Rating-- -4F to 221F [-20C to 105C] Part Number 1604040-1 1604039-1 1604041-1 1604038-1 Voltage Key Color Chart Housing Color Yellow Orange Red Gray Blue Black Related Product Data Accessories--page 15 Application Tooling--page 16 Technical Documents--page 26 Voltage 12 V 18 V 24 V 36 V 48 V 80 V Color code given for various voltages is only a suggestion, other codes and keys available upon request. 11 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 180 Connectors (Single-Pole) Product Facts Cold-headed Contact Single-Pole Housing n Color-coded modular housings: blue, black, white, red and green n Genderless housings reduce inventory n Contact wire range: 1/0, 1, 2, 4 AWG n Integral stainless steel locking spring in housing for contact retention n Built-in interlocking features (dovetails) allow stacking and wire routing n Reducing bushings down to 10 gauge US n File No. E28476 C .5.016 [12.70.4] TYCO 2.35 .03 [59.80.8] Dia. 3.25 [82.6] 1.01 [25.6] Inside Diameter .516.005 [13.10.13] for 1/0 AWG .512.005 [13.00.13] for 1 AWG, 2 AWG, and 4 AWG .93 [23.5] 1.07 [27.2] (R) Series 180 (Single-Pole) Material and Finish Housing Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Mounting Clamp Sets--Aluminum Reducing Bushings--Copper with silver plating Color Blue Black White Red Green 1 Electrical Characteristics 2 Part Number 1604062-1 1604062-2 1604062-3 1604062-4 1604062-5 4 AWG 1604395-1 1604395-2 1604395-3 1604395-4 1604395-5 Connector Kit Part Numbers1,2 2 AWG 1 AWG 1604396-1 1604397-1 1604396-2 1604397-2 1604396-3 1604397-3 1604396-4 1604397-4 1604396-5 1604397-5 1/0 AWG 1604398-1 1604398-2 1604398-3 1604398-4 1604398-5 1 Housing and 1 contact. Housings and contacts are bulk packaged. Current Carrying Capability-- (1/0 AWG Wire) 1 x 1 -- 180 A, 84.9F [29.4C] T-Rise 2 x 1 -- 165 A, 78.3F [25.7C] T-Rise 2 x 2 -- 150 A, 76.6F [24.8C] T-Rise Voltage Rating--600 V (both AC and DC) Dielectric Withstanding Voltage-- 2200 VDC Avg. Initial Contact Resistance-- 100 micro-ohms Contacts (Cold-headed) Wire Size 4 AWG 2 AWG 1 AWG 1/0 AWG Part Number 1604040-1 1604039-1 1604041-1 1604038-1 Mechanical Characteristics Average Mating/Unmating Force--20 lb. [89 N] Max. Wire Insulation Diameter-- .900 [22.86] Wire Size Range--1/0, 1, 2, 4 AWG [53, 40, 35, 21 mm2] Contact Retention--170 lb. [756 N] Temperature Rating-- -4F to 221F [-20C to 105C] Related Product Data Accessories--page 15 Application Tooling--page 16 Technical Documents--page 26 12 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series 350 Connectors (2-Pole Battery) 2-Pole Housing Product Facts Cold-headed Contact n Color-coded UL 94V-0 housings: yellow, orange, red, gray, blue, and green n Keying feature helps prevent two different voltage color-coded housings from mating n Genderless housings reduce inventory n Contact wire range: 1/0, 2/0, 3/0, 4/0, 300 MCM n Replaceable contacts n Integral stainless steel locking spring in housing for contact retention US n File No. E28476 C .811.016 [20.60.4] .256 Dia. [6.5] 2 holes 3.083.004 [78.31.0] 1.299.02 [33.00.5] 1.38 [35.0] .961 Dia. [24.4] 1.14 [29.0] 4.23 [107.46] * *Inside Diameter .4370.004 [11.10 +/- 0.10] for 1/0 AWG .4880.004 [12.40 +/- 0.10] for 2/0 AWG .5790.004 [14.70 +/- 0.10] for 3/0 AWG .6420.004 [16.30 +/- 0.10] for 4/0 AWG .7520.004 [19.10 +/- 0.10] for 300 MCM (R) 1.31 [33.2] Note: 300 MCM contact dimensions shown, unless otherwise noted. Material and Finish Series 350 (2-Pole) Housing--Polycarbonate, UL 94V-0 Retaining Spring--Stainless Steel Contacts--Copper with silver plating Reducing Bushings--Copper with silver plating Housing Color Part Number Yellow 1604050-1 Orange 1604050-2 Red 1604050-3 Gray 1604050-4 Blue 1604050-5 Green 1604050-6 Electrical Characteristics Current Carrying Capability-- 275 amp @ 83.3F [28.5C] T-Rise with 4/0 AWG wire Voltage Rating--600 V, AC or DC Dielectric Withstanding Voltage-- 2200 VDC Average Initial Contact Resistance--50 micro-ohms 1 2 1/0 AWG 1604060-1 1604060-2 1604060-3 1604060-4 1604060-5 1604060-6 Connector Kit Part Numbers1,2 2/0 AWG 3/0 AWG 4/0 AWG 1604059-1 1604058-1 1604057-1 1604059-2 1604058-2 1604057-2 1604059-3 1604058-3 1604057-3 1604059-4 1604058-4 1604057-4 1604059-5 1604058-5 1604057-5 1604059-6 1604058-6 1604057-6 300 MCM 1604056-1 1604056-2 1604056-3 1604056-4 1604056-5 1604056-6 1 Housing and 2 contacts. Housings and contacts are bulk packaged. Contacts (Cold-headed) Wire Size 1/0 AWG 2/0 AWG 3/0 AWG 4/0 AWG 300 MCM Mechanical Characteristics Contact Retention--500 lbs. [2224.1 N] Average Mating/Unmating Force--30 lbs. [133.5 N] Max. Wire Insulation Diameter-- 1.10 [27.94] Temperature Rating-- -4F to 221F [-20C to 105C] Wire Size Range--1/0, 2/0, 3/0, 4/0, 300 MCM [53, 67, 85, 107, 152 mm2] Part Number 1604055-1 1604054-1 1604053-1 1604052-1 1604051-1 Voltage Key Color Chart Related Product Data Accessories--page 15 Application Tooling--page 16 Technical Documents--page 26 Reducing Bushing--(1/0 to 2/0 AWG) Part No. 1604121-6 Cable Clamp--Part No. 647688-1 Housing Color Voltage Yellow Orange Red Gray Blue Green 12V 18V 24V 36V 48V 72V Color code given for various voltages is only a suggestion, other codes and keys available upon request. 13 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series Accessories Series 15/30/45 Hardware Kits Series 15/30/45 Accessories Part Number Description Part Number Mounting Wings 1445960-1 Red, UL 94V-0 Spacers 1445959-1 Red, UL 94V-0, Short 1445959-2 Red, UL 94V-0, Long Retaining Pins for use with 15 A/30 A/45 A 1445886-4 .25 [6.35] length 1445886-5 .44 [11.18] length 1445886-6 .85 [21.6] length Series 15/30/45 Mounting Wings Description Plug and Receptacle Housings 1604077-1 Receptacle, 2, 3, 4 pole 1604078-1 Receptacle, 5, 6 pole 1604079-1 Receptacle, 7, 8 pole 1604080-1 Plug Frame without Latch, 2, 3, 4 pole 1604081-1 Plug Frame without Latch, 5, 6 pole 1604082-1 Plug Frame without Latch, 7, 8 pole 1604083-1 Plug Frame with Latch, 2, 3, 4 pole Plug Frame with Latch, 5, 6 pole 1604084-1 Plug Frame with Latch, 7, 8 pole 1604085-1 Part Number Description Hardware Kits (Cable clamp, screws & retaining pins) 647747-3 647747-2 647747-1 4 pole 6 pole 8 pole Series 50 Accessories Part Number 647746-1 1744077-1 647745-1 647743-1 647765-1 Description Plastic Handle & Screw Kit, Red Dust Cover, Black Strain Relief Cable Clamp Kit, #6 & #8 AWG Strain Relief Cable Clamp Kit, #10 & #12 AWG Strain Relief Cable Clamp Kit, Single Conductor #6 Please contact Product Engineering or Product Management for availability. Reducing Bushings Wire Size (AWG) 6 to 8 6 to 10-12 6 to 14-16 Part Number 1445762-1 647840-1 1445763-1 (permits use of smaller wires with 6 AWG contact Part Number 647877-1) Series 75 Accessories Part Number Mounting Wings 1445729-1 1445729-2 Description Blue, oval mounting hole Blue, round mounting hole Retaining Pins for use with 75 A/120 A/180 A 1445886-1 75 A/120 A/180 A hsgs, 1 high block 75 A/120 A/180 A hsgs, 2 high block 1445886-2 75 A/120 A/180 A hsgs, 3 high block 1445886-3 Reducing Bushings for Series 50 A and 75 A 1445762-1 6 to 8 AWG 647840-1 6 to 10-12 AWG 6 to 14-16 AWG 1445763-1 Mounting clamp set part numbers available. 14 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series Accessories (Continued) Series 120 Panel Mounting Clamp Series 175 & 350 Handle Kit Series 120 Accessories Part Number Type Description Retaining Pins for use with 75A/120A/180A 1445886-1 Single-Pole Single-Pole 1445886-2 1 high block 2 high block Reducing Bushings 1604072-3 1604072-2 1604072-1 2 to 4 AWG 2 to 6 AWG 2 to 8 AWG Single/2-Pole Single/2-Pole Single/2-Pole Mounting Clamp Sets 647721-1 647722-1 Single-Pole Single-Pole Panel Mounting Clamp 1744090-1 2-Pole 2- & 4- pole configuration 3-pole configuration -- Series 175, 180 & 350 Accessories Part Number Reducing Bushings 1604121-1 1604121-2 1604121-5 1604121-4 1604121-3 1604121-6 Handle Kit 647737-1 647737-2 1-647737-1 1-647737-2 Type Description 175/180 175/180 175/180 175/180 175/180 350 10 to 1/0 AWG 6 to 1/0 AWG 4 to 1/0 AWG 2 to 1/0 AWG 1 to 1/0 AWG 1/0 to 2/0 AWG 175 2-Pole 175 2-Pole 350 2-Pole 350 2-Pole Red Gray Red Gray Series 175 & 180 Accessories Part Number Series 175 Dust Cover Assembly Type Description Cable Clamps 647700-1 647703-1 647697-1 647688-1 647695-1 647720-1 647719-1 Clamp Clamp Clamp 350 180 180 180 Single Conductor 2 Single Conductors Twin Conductor Cable Cable Clamp Single pole version 2 pole version 3 pole version Dust Cover 647691-1 647692-1 175 175 Dust Cover Assembly (Shown) Dust Cover Housing 15 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series Tooling AMP-O-LECTRIC Model "G" Terminating Machines, Part Nos. 354500-1, -9, -11 (409-5842) Semiautomatic bench machines for crimping reeled terminals and contacts, featuring a quiet and reliable direct motor drive, microprocessor controls for ease of setup and operation, and guarding and lighting designed for operator convenience and safety. All models are equipped with either manual or automatic precision adjustment of crimp height. Machinemounted sensors are available for crimp quality monitoring using conventional miniature-style applicators. For more information, request Catalog 65828, Video 198116, Catalog 82275 [Crimp Quality Monitor (CQM)], Video 198094. AMP-O-LECTRIC Model "K" Terminating Machine Part No. 1-471273-3 (409-5128) AMP-O-LECTRIC Model "K" Terminating Machine with a permanently-mounted applicator that accepts interchangeable die sets to apply a variety of tapemounted terminals and splices. Many of the die sets can also be used in AMP-O-LECTRIC Terminating Machines with a tape applicator. n AMP 3K/40 and AMP 5K/40 Terminating Machines (409-10047) n n n n n The AMP 3K/40 and AMP 5K/40 Terminators are designed for customers that require the increased output and quality of a semiautomatic machine at a competitive price. By incorporating the most commonly requested features as standard and offering a long list of optional equipment, these terminators offer flexibility to meet the specific needs of various applications at the lowest possible cost. Stripping Module (for the AMP 3K/40 and AMP 5K/40 Terminating Machines and AMP-O-LECTRIC Model "G" Terminator) 112075-2 For more information, contact Tyco Electronics. 3,000 lb [1361 kg] max. crimp force (AMP 3K/40); 5,000 lb [2268 kg] max. crimp force (AMP 5K/40) Toolless removal of applicators and guards Jog capability Quiet, fast operation -- 80/76 dBA and cycle time less than 0.400 seconds Accepts Heavy Duty Mini stye applicators Wide range of optional equipment such as toolless precision crimp height adjust, batch counter, CQM capability and work light For more information, request Catalog 1654856. The combination of the Stripping Module with the AMP 3K/40 and AMP 5K/40 Terminating Machines or the AMP-O-LECTRIC Model "G" Terminator provides an economic and proficient method of stripping the wire and crimping terminals on the same machine. The module accepts Endand Side-Feed HDM Applicators (32-14 AWG) and operates in three modes: crimp only, strip only, or strip and crimp. It can be installed on existing machines in the field or purchased as one unit from the factory. For more information, request Catalog 1309085. 16 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMP Power Series Tooling (Continued) The Semiautomatic Power Power Applicator Applicator is designed to Part Number 68296-1 (Customer Manual 409-2661) produce a carefully controlled uniform pressure crimp while providing a high rate of production. The applicator features matching dies that fully bottom at the completion of the crimp to provide proper crimp height. The one die set is fully adjustable to provide the full range of crimp heights for all wire sizes. 500 MCM Heavy Duty Cable Cutter Part No. 605742-1 (408-4557) Cable Insulation Stripper/Slitter Part No. 606700-1 (408-9688) * Designed to cut aluminum or copper cable up to 500 MCM. * Used on single or multiple conductor cable up to 1.75" in diameter * Light weight tubular steel handles with hand grips Contact Extraction Tool Part No. 68265-1 or standard insulated screwdriver * 21" overall length Hand Tools for Cold-headed Contacts and Heavy-Duty Lug Terminals (Single-Indent Crimp) Tyco Electronics American Electrical Terminal (AET) Crimp Tool Part No. 1526955-1 OR Crimp Tool Part No. T-406 Includes Adapter Includes Adapter For AMP Power Series 50 and 75 Contacts Wire Size Strip Length (AWG) 6 .475-.525 8 [12.06-13.33] 10-12 -- Part No. Part Number Marking Part Number Marking 647877-1 647878-1 647879-1 1527508-1 A 5992 A -- -- 1527507-1 B 5991 B 1527505-1 C 5989 C No Adapter -- No Adapter -- Also For Heavy-Duty Lug Terminals (See pages 28, 29) Wire Size (AWG) 6 Strip Length 7/16 [11.11] 4 1/2 [12.70] 1/0 2/0 2 1 3/0 4/0 11/16 [17.46] 11/16 [17.46] 9/16 [14.29] 5/8 [15.87] 3/4 [19.05] 13/16 [20.64] Pneumatic Tools for Cold-headed Contacts (Dual-Indent Crimp) and Heavy-Duty Lug Terminals (See pages 28, 29) AMP Power Series Contacts Series Wire Size (AWG) Part No. 647877-1 6 647878-1 8 50/50 FPR/75 10-12 647879-1 2 1445995-1 120 4 1445996-1 6 1445997-1 400 Series Power Unit Preferred Alternate 400-BEC 400-BHD 400-BEC 400-BHD PICO* Pneumatic Tools** Locator Die Preferred Alternate 414DA-4583 414DA-4583 4582-1 9616-1 414DA-4582 Closure Dim. .152 [3.86] .152 [3.86] .134 [3.40] 414DA-4580 4580-1 None .200 [5.08] 500 Series Power Unit 50/50 FPR/75 120 175/180 350 6 8 10-12 647877-1 647878-1 647879-1 2 4 6 1/0 2 4 1 300 MCM 4/0 3/0 2/0 1/0 1445995-1 1445996-1 1445997-1 1604038-1 1604039-1 1604040-1 1604041-1 1604051-1 1604052-1 1604053-1 1604054-1 1604055-1 500-DEC 500-D 514DA-7033 514DA-7033 514DA-7034 7033-1 7034-1 .152 [3.86] .152 [3.86] .134 [3.40] 500-DEC 500-D 514DA-7035 7035-1 None .200 [5.08] 10034-1 None .250 [6.35] None .525 .400 .360 .325 .250 500-DEC 500-DEC 500-D 500-D 514DA-10023 514DA-10024 514DA-10025 514DA-10026 514DA-10027 514DA-10026 514DA-10025 514DA-10024 514DA-10023 10023-2 10023-2 10023-2 10023-1 10023-1 [13.34] [10.16] [9.14] [8.26] [6.35] * Pacific Industrial Components (PICO) Corporation, 444 Constitution Ave., Camarillo, CA 93012-8505; Tel: (805) 388-5510 ** Pneumatic Tool consists of a power unit, die, and locator; it can be used as a portable hand tool, bench-mounted hand tool, or foot-controlled unit. 17 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Wire Connectors Product Facts n n n n n n n n n Rated to 600 VAC (RMS) Flame retardant housings 94V-0 Housings, adapters, and power terminals keyed for proper assembly Stackable housings provide easy wire routing and neat wire dressing Built-in interlocking features better resist shock and vibration Usable as in-line connector, or as panel and surface mount connector Available in six different colors for circuit coding and identification Choice of two power terminals accommodates 10-12 AWG and 14-16-18 AWG conductors Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 R n n CSA Certified, File No. LR7189 R VDE Registered #5133 AMPINNERGY Wire-ToWire (WTW) Connectors provide a reliable and efficient means of interconnecting conductors employed to carry up to 600 VAC in power circuits or networks. The WTW Connectors consist of mating hermaphroditic, flame retardant polycarbonate housings into which customer terminated power contacts are inserted. Stackable in four directions through the use of molded interlocking keyways, the connectors make wire routing and dressing orderly and easy to accomplish. More importantly, the built-in interlocking features on the connectors and the accessory mounting adapters provide better resistance to the effects of shock and vibration, keeping the interconnect more stable and secure. The design features of the WTW Connector make it easily applicable to free hanging, surface mounted or panel mounted applications. By simply sliding the accessory mounting adapters into the molded keyways of the connector housing, a free hanging connector can be transformed into a surface mount connector or a panel mount connector. Customer supplied 8-32 screws and nuts may be used to secure the connectors configured with the mounting adapters to printed circuit boards or distribution panels. The same hardware may be used to secure the connectors to pre-cut openings in the panels. Furthermore, WTW Connector housings, mounting adapters and power terminals are all provided with alignment or keying features that make it difficult to improperly assemble and apply the connector. Alignment slots and tabs on the plastic connector housings provide for easy mating of the housings, even in the dark! Mounting adapters have a keyway on one side and a key on the other side providing for easy assembly to the connector by touch alone if necessary. And the power terminals have a side tab that helps prevent the incorrect insertion of the terminated conductor into the housing. Once inserted, the contacts firmly latch within the connector housing. The WTW Connector system is available in six different and distinctive colors which makes circuit differentiation and identification possible. The crimped power terminals will accommodate either 10-12 AWG or 14-16-18 AWG stranded conductors. Depending upon the conductor size and the number of conductors in the connector configuration, the current rating ranges from 10 amperes to 55 amperes. Technical Documents Product Specification 108-1373 AMPINNERGY WTW Connectors Application Specification 114-6051 Instruction Sheets 408-3277 AMPINNERGY Wire-To-Wire Stackable Connectors 408-3198 Inspection of AMPINNERGY System Power Contacts 18 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Wire Connectors (Continued) Housings Material and Finish Housing -- Polycarbonate, 94V-0 For surface mounting and panel mounting information, see Instruction Sheet 408-3277, AMPINNERGY Wire-To-Wire Stackable Connectors. Free Hanging Interconnections Customer terminated power contacts are inserted into housings Color White Black Green Red Blue Gray 1.453 [36.91] Housing Part Numbers 556137-1 556137-2 556137-3 556137-4 556137-6 556137-8 Key Keyway .386 [9.80] .386 [9.80] Wire-To-Wire Connector Housing Mounting Adapters .696 [17.68] Part Number 557313-1 .177 [4.50] .294 [7.47] Material and Finish: .200 [5.08] .466 [11.84] Housing -- Polycarbonate, Black Two mounting adpaters can be used with one or more connector housings to provide thru-panel or horizontal surface mounting capability of the completed assembly. .190 [4.83] Keyway .211 [5.36] .231 [5.87] .405 [10.29] External Locking Latch Clip Part Number 557640-1 AMPINNERGY Wire-To-Wire Connector Housings have an integral locking feature designed to keep housings mated in most applications. Hower, the External Locking Latch Clip may be used as needed in applications where severe vibration or tension may pull mated housings apart. AMPINNERGY Wire-To-Wire Clips Part Number 557640-1 AMPINNERGY Wire-To-Wire Clips (Installed) Part Number 557640-1 19 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Wire Connectors (Continued) Power Terminals Loose Piece Material and Finish Part Number 556136-2 Contacts -- Copper alloy plated with .000100 [0.00254] minimum tin The Wire-To-Wire Connector Power Contacts are available in either strip form or in loose piece form. Contacts in strip form are terminated on continuous feed type terminators and the loose piece contacts are terminated with the hand tool or pneumatic tool. For wire preparation and crimped contact inspection information, refer to Instruction Sheet 408-3198, Inspection of AMPINNERGY System Power Contacts. Part Number 556135-2 Contact Part Numbers 556135-2 (loose piece) 556136-2 (loose piece) Wire Size (AWG) 18-16 14 12 10 Hand Tool Part Number Pneumatic Tool Part Numbers 69710-1 189721-2* Die Set Part Numbers 58493-1 58492-1 58490-1 58491-1 *Requires "C" Head Adapter Part No. 318161-1 and Adapter Holder Part No. 189928-1. See Catalog 124208 for more information. Note: The same Hand Tool or Pneumatic Tool and Die Sets may be used to apply the Wire-To-Board Connector Terminals. Strip Form .145 [3.69] Part Number 556135-1 .730 Nominal [18.54] Feed Length .265 [6.74] .145 [3.69] Part Number 556136-1 .140 [3.56] Part Number 788109-1 .140 [3.56] Part Number 788110-1 .730 Nominal [18.54] Feed Length .263 [6.68] Contact Part Numbers Wire Size (AWG) AMP-O-LECTRIC Model G Terminating Machine Applicator Part Numbers 556135-1 (strip) 18-16-14 354500-1 567403-3 556136-1 (strip) 10-12 354500-1 567256-6 788109-1 (strip) 18-14 354500-1 680447-3 788110-1 (strip) 10-12 354500-1 680449-3 20 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Board Connectors Product Facts n n n n n n n n n n n n Ratings: 600 VAC (RMS), current ratings range from 12-35 amps Receptacles polarized to plug Receptacles and plugs available in contact configurations of 2 through 8 positions Vertical receptacle polarized to PCB Receptacle contacts have dual solder posts for efficient heat dissipation, low millivolt drop and mechanical strength Receptacles may be mounted on PCBs .062 to .125 inch thick Plugs have positive latching to receptacles Removable crimp contacts latch firmly in plug Plugs are one-piece design Two ranges of crimped contacts accommodate either 10-12 AWG or 14-16-18 AWG conductors UL Recognized, File No. E28476 CSA Certified, File No. LR7189-239 R R AMPINNERGY Wire-To-Board (WTB) Connectors Connectors provide a convenient and efficient means of delivering up to 600 VAC to component printed circuit boards and other power distribution devices in computers and peripherals, telephone systems and appliances. The WTB connectors also have automotive and industrial applications. Receptacles Technical Documents Product Specification 108-1349 AMPINNERGY WTB Connectors Application Specification 114-6044 AMPINNERGY WTB Connectors Instruction Sheets 408-3236 Installation of AMPINNERGY WTB Connectors 408-3198 Inspection of AMPINNERGY Contacts The AMPINNERGY WTB connector receptacles can be installed on pc boards varying in thickness from .062 inch to .125 inch. A polarizing pin is provided on the vertical receptacle assembly to aid in proper positioning on the pc board. Both the vertical and right-angle assemblies are polarized for accurate mating to the plug assemblies. The receptacle assemblies are available in contact configurations ranging from two to eight positions. Plugs The single piece plug housings are available in contact configurations to mate with the receptacles. The plug is equipped with positive latches to allow full and more secure mating to the respective receptacle. A make-first/break-last feature is designed into position 1 of the plug assemblies to provide grounding protection. Contacts The crimp contacts will accommodate either 1012 AWG or 14-16-18 AWG conductors. The contacts latch firmly within the plug housing. 21 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Board Connectors (Continued) Vertical PCB Receptacles Product Facts n n n n n n n n Withstands vapor phase, infrared and wave soldering processes .040 minimum standoff to PCB Polarized to PCB; to plug Contact centerline spacing: .440 Overall height on PCB: .600 Fits PCB thickness .062 through .125 Contacts have dual solder posts for efficient heat dissipation, low millivolt drop and mechanical strength Positive latching to mating plug .451 [11.46] Material and Finish .050 [1.27] Typ. .440 [11.18] Housing -- Polyphenylene Sulfide, Black, 94V-0 Contacts -- Tin Plated Copper Alloy Dim. A Housing .568 [14.43] .192 [4.90] .050 [1.27] Typ. .065 [1.66] .100 [2.54] Typ. Contact Dim. B Dim. C .130.005 [3.30.13] .175 [4.45] .110.005 [2.79.13] .070.003 [1.78.08] .440 [11.18] Typ. .510 [12.95] .130.005 [3.30.13] .100 [2.54] Typ. Dim. B PCB Thickness -- .062-.125 No. of Positions 2 3 4 5 PCB Thickness -- .250 No. of Positions 4 6 Receptacle Part Numbers 558574-1 558084-1 6 7 8 Dimensions A B C .93 23.50 1.37 34.68 1.81 45.85 2.25 57.03 2.69 68.20 3.13 79.38 3.57 90.56 1.56 39.62 2.00 50.80 2.44 61.98 2.88 73.15 3.32 84.33 3.76 95.50 4.20 106.68 1.84 46.61 2.28 57.79 2.72 68.97 3.16 80.14 3.60 91.32 4.04 102.49 4.48 113.67 Receptacle Part Numbers 556881-2 556881-3 556881-4 556881-5 556881-6 556881-7 556881-8 22 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Board Connectors (Continued) Right-Angle PCB Receptacles Product Facts n n n n n n n n Withstands vapor phase, infrared and wave soldering processes .040 minimum standoff to PCB Receptacles polarized to plug Contact centerline spacing: .440 Overall height on PCB: .600 Fits PCB thickness .062 through .125 Contacts have dual solder posts for efficient heat dissipation, low millivolt drop and mechanical strength .065 [1.66] .200 [5.08] Typ. .568 [14.43] Positive latching to mating plug Dim. A Dim. B Dim. C Material and Finish Housing .440 [11.18] Housing -- Polyphenylene Sulfide, Black, 94V-0 Contacts -- Tin Plated Copper Alloy .501 [12.73] .192 [4.90] Typ. .050 [1.27] Typ. .100 [2.54] Typ. Contact .200 [5.08] .440 [11.18] .510 [12.95] .100 [2.54] .063.003 [1.60.08] .130.005 [3.30.13] .130.005 [3.30.13] Dim. B PCB Thickness -- .062-.125 Dimensions No. of Positions 2 3 4 5 6 7 8 A B C .93 23.50 1.37 34.68 1.81 45.85 2.25 57.03 2.69 68.20 3.13 79.38 3.57 90.56 1.56 39.62 2.00 50.80 2.44 61.98 2.88 73.15 3.32 84.33 3.76 95.50 4.20 106.68 1.84 46.61 2.28 57.79 2.72 68.97 3.16 80.14 3.60 91.32 4.04 102.49 4.48 113.67 Receptacle Part Numbers 556882-2 556882-3 556882-4 556882-5 556882-6 556882-7 556882-8 23 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Board Connectors (Continued) Plug Housings Product Facts n n n n n One-piece housing Polarized to mating receptacles Positive latching to mating receptacles Accepts crimp contacts P/N 556880-2 and 556883-1 Internal latching of crimp contact Material Housing -- Polycarbonate, Black, 94V-0 Dim. A 1.443 [36.66] Dim. B .305 [7.75] .371 [9.43] .440 [11.18] No. of Positions 2 3 4 5 6 7 8 Dimensions A .85 21.42 1.29 32.59 1.73 43.77 2.17 54.94 2.61 77.30 3.05 77.30 3.49 88.47 B 1.20 30.31 1.64 41.48 2.08 52.66 2.52 63.83 2.96 75.01 3.40 86.19 3.84 97.36 Plug Part Numbers 556879-2 556879-3 556879-4 556879-5 556879-6 556879-7 556879-8 24 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications AMPINNERGY Wire-To-Board Connectors (Continued) Crimp Contacts Product Facts n Contacts are dual beam design Material and Finish Contacts--Tin Plated Copper Alloy Wire barrel accepts one 10 or 12 AWG stranded copper conductor .735 [18.67] Part Number 556880-2 Strip Part Number 556880-1 Loose Piece Application Tooling Applicator Part No. 567256-3 (for Lead Makers) 567256-4 (for AMP-O-LECTRIC Model K Machine) 567256-6 (for AMP-O-LECTRIC Model G Machine) .244 [6.20] 1.073 [27.26] .256 [6.51] .145 [3.70] Wire barrel accepts one 14, 16 or 18 AWG stranded copper conductor .735 [18.67] Part Number 556883-1 Loose Piece Part Number 556883-2 Strip .244 [6.20] Application Tooling Part No. 69710-1 Hand Tool 58492-1 Die Set (14 AWG) 58493-1 Die Set (18-16 AWG) 91308-1 Extraction Tool .145 [3.70] 1.073 [27.26] .169 [4.30] 25 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications Technical Documents Various technical documents are available for your use: Product Specifications describe technical performance characteristics and verification tests. They are intended for the Design, Component and Quality Engineer. 108-1349 108-1373 AMPINNERGY WTB Connectors AMPINNERGY WTW Connectors Application Specifications describe requirements for using the product in its intended application and/or crimping information. They are intended for the Packaging and Design Engineer and the Machine Setup Person. 114-6044 114-6051 114-13071 114-13107 114-13118 114-13119 114-13127 114-13149 AMPINNERGY WTB Connectors AMPINNERGY WTW Connectors AMP Power Series 50 (Double-Pole) and 75 (Single Pole) Connector Assemblies AMP Power Series 120 (Single- and Double-Pole) Connector Assemblies AMP Power Series 175 (Double-Pole) and 180 (Single-Pole) Connector Assemblies AMP Power Series 350 (Double-Pole) Connector Assemblies AMP Power Series 15, 30 and 45 (Single-Pole) Connector Assemblies AMP Power Series 180 (Single-Pole) Connector Assemblies Instruction Sheets provide instructions for assembling or applying the product. They are intended for the Manufacturing Assembler or Operator. 408-3198 408-3236 408-3277 408-8636 408-8868 Inspection of AMPINNERGY System Power Contacts Installation of AMPINNERGY WTB Connectors AMPINNERGY Wire-To-Wire Stackable Connectors AMP Power Series 50 Connector Assemblies AMP Power Series 175 and 350 Connector Assemblies with Cable Clamp Kits 408-4557 408-4559 408-4561 408-8540 408-9688 408-9816 Heavy Duty Cable Cutter Hand Tool 605743-1 Heavy Duty Cable Cutter Hand Tool 605744-1 Heavy Duty Cable Cutter Hand Tool 600769-1 Crimp Tool 1526955-1 Cable Stripper/Slitter Tool 606700-1 Handling of Reeled Products Test Summary 502-1136 502-1160 502-1166 502-1167 502-1172 502-1173 50/75 Product Evaluation 15/30/45 Product Evaluation 120 Product Evaluation 120 Competitive Evaluation AMP Power Series 175/180 Product Evaluation AMP Power Series 350 Product Evaluation Customer Manual 409-5128 AMP-O-LECTRIC Model K Terminator Machine 1-471273-2 26 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications Part Number Index Note: This numerical index lists all cataloged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. Part No. 556135 556136 556137 556879 556880 556881 556882 556883 557313 557640 558084 558574 647688 647691 647692 647695 647697 647700 647703 647719 647720 647721 647722 647737 647743 647745 647746 647747 647754 647755 647756 647765 647840 647845 647877 647878 647879 647892 647893 680447 680449 788109 788110 1445715 1445716 1445729 1445762 1445763 1445886 1445957 1445959 1445960 1445962 1445994 1445995 1445996 1445997 1445998 1445999 1446000 1604001 Page 20 20 19 24 24,25 22 23 24,25 19 19 22 22 13,15 15 15 15 15 15 15 15 15 15 15 15 14 14 14 14 6,7,8 6,7,8 6,7,8 14 14 6 6,7,8,14 6,7,8 6,7,8 6 6 20 20 20 20 8 8 14 14 14 14,15 5 14 14 5 10 9,10, 17 9,10, 17 9,10, 17 10 10 10 9 Part No. 1604002 1604037 1604038 1604039 1604040 1604041 1604042 1604043 1604044 1604045 1604050 1604051 1604052 1604053 1604054 1604055 1604056 1604057 1604058 1604059 1604060 1604062 1604072 1604077 1604078 1604079 1604080 1604081 1604082 1604083 1604084 1604085 1604112 1604113 1604121 1604342 1604395 1604396 1604397 1604398 1604433 1744041 1744042 1744077 1744090 Page 9 11 11,12, 17 11,12, 17 11,12, 17 11,12, 17 11 11 11 11 13 13, 17 13, 17 13, 17 13, 17 13, 17 13 13 13 13 13 12 15 14 14 14 14 14 14 14 14 14 5 5 13, 15 7 12 12 12 12 6,7,8 5 5 14 15 Tooling Part No. Page 5989 5991 5992 58490 58491 58492 58493 68250 68265 68296 68313 68344 69710 91308 189721 189928 318161 354500 471273 567256 567403 600769 605742 605743 605744 606700 1385450 1385468 1385469 1385663 1385664 1526955 1527505 1527507 1527508 T-406 17 17 17 20 20 20,25 20,25 8 17 6,7,17 8 8 20,25 25 20 20 20 16,20 16,26 20,25 20 26 17 26 26 17,26 5 5 5 6,7,8 6,7,8 6,7,8,17,26 17 17 17 17 27 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications Related Product Catalogs Heavy Duty Seamless Terminals and Splices Catalog 1308674 The Heavy Duty Seamless and Copper Compression Lug and Splice line provides a robust terminal line for applications in the many industries. The product is used in applications including industrial and welding equipment, transportation/ marine cable harness, and general-purpose harnesses. The Heavy Duty Seamless line utilizes deep-draw stamping technology to create a robust terminal without butted seams along the wire barrel or along the outer edge of the ring tongue. The Standard Terminals and Splices Catalog 82042 AMP solderless terminals and splices meet or exceed today's standards for reliable termination in applications ranging from control circuits to heavy duty power wiring. The catalog describes only standard terminals and splices accommodating wire sizes from 26 AWG through 4/0 AWG AMPOWER Terminals and Splices Catalog 82025 The AMPOWER product line is available in a variety of terminal and splice styles to suit your design requirements. Heavy Duty Splice line offers butt splice versions with either flared or chamfered wire barrels for ease of wire entry and dimpled wire stops to assist in proper wire placement. The Copper Compression Lug and Splice line is a formed tubular line for use on cable assemblies in Commercial equipment and Industrial machinery. The thicker tongue and wire barrel of this line provide added strength and rigidity for more challenging applications. The Battery Lug and Splice line offers the thickest material and strength for your industrial equipment and transportation harness applications. Tyco Electronics has extensive drawn sleeve capabilities to help meet your customized electrical sleeve needs. The company manufactures specialized sleeves used in general electrical application and electrical components. Tyco Electronics has the capability to manufacture sleeves in a range of copper alloys and has extensive post electroplating capabilities. Contact us to review your application and discuss the benefits we can provide. The terminals are pre-insulated and color coded by wire size for easy identification. AMP's special plating process creates a high resistance to corrosion Funnel entry on many terminals allows for easy wire insertion for high speed production Use of AMP application tooling is designed for uniform high quality terminations UL, CSA, Military Approved Nylon or vinyl insulation provides high dielectric strength The serration or dimple feature inside the terminal barrel provides maximum barrel contact and tensile strength AMPOWER terminals and splices are ideally suited for power generation and distribution. This makes electrical equipment subject to continuous operation, such as generators, motors and welders, a perfect application for AMPOWER products. In addition, other applications include interconnections of power supplies to computers and peripheral equipment. 28 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications Related Product Catalogs (Continued) SOLISTRAND, Budget and DIAMOND GRIP Uninsulated Terminals and Splices Catalog 65505 SOLISTRAND and Budget terminals and splices are specially designed to terminate solid and stranded wire, irregular shaped conductors, and combinations of these - retaining the superior performance characteristics of single-purpose terminals and splices. Tyco Electronics Power Connectors and Interconnection Systems Catalog 1773096 Tyco Electronics Power Connectors and Interconnection Systems Catalog 1773096 features the largest grouping of high performance power connectors from Tyco Electronics. Most of the products are geared specifically for the high-end Corrosion resistance, vibration resistance and tensile strength of these terminals and splices are well within the limits of commercial and military specifications. The Budget terminal is primarily the same as the SOLISTRAND terminals without the brazed seam in the wire barrel. These terminals and splices fulfill the need for an economical and electrically superior computer and telecommunications equipment markets, however, products for Industrial applications are included as well. The catalog includes power connectors mounted to printed circuit boards, discrete wires/cable assemblies and bus-bars. The "applications served" includes bulk power distribution from modular power supplies, low inductance con- termination where extreme vibration and tension on the wires are not present. DIAMOND GRIP utilizes a tin plated copper insulation support sleeve with "V" notches. The sleeve eliminates fraying of the insulation or breaking of the conductor. The "V" notches lock the wire insulation against vibration and pullout. nectors designed for microprocessor power delivery, backplane power interconnects meeting today's latest industry standards, and more. The newest products sold under the AMP and ELCON brands are now combined into a single comprehensive catalog. 29 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Power Connectors for Industrial and Commercial Applications Engineering Notes 30 Catalog 1308885 Issued 3-05 www.tycoelectronics.com Dimensions are in inches and millimeters unless otherwise specified. Values in brackets are metric equivalents. Dimensions are shown for reference purposes only. Specifications subject to change. USA: 1-800-522-6752 Canada: 1-905-470-4425 Mexico: 01-800-733-8926 C. America: 52-55-5-729-0425 South America: 55-11-3611-1514 Hong Kong: 852-2735-1628 Japan: 81-44-844-8013 UK: 44-141-810-8967 Global Contacts Americas Argentina - Buenos Aires Phone: +54-11-4733-2200 Fax: +54-11-4733-2211 Brasil - Sao Paulo Phone: +55-11-3611-1311 Fax: +55-11-3611-0397 Canada - Markham Phone: +905-475-6222 Fax: +905-474-5520 Product Information Center: (Technical Support) Phone: +905-470-4425 Fax: +905-474-5525 Colombia - Bogota Phone: +57-1-231-9398 Fax: +57-1-660-0206 Mexico - Mexico City Phone: +52-55-5-729-0400 Fax: +52-55-5-361-8545 For Latin/South American Countries not shown Phone: +57-11-4733-2015 Fax: +57-11-4733-2083 United States - Harrisburg, PA Phone: +717-564-0100 Fax: +717-986-7575 Product Information Center: (Technical Support) Phone: +800-522-6752 Fax: +717-986-7575 Asia/ Pacific Australia - Sydney Phone: +61-2-9554-2600 Fax: +61-2-9502-2556 Product Information Center: (Technical Support) Phone: +61-2-9554-2600 Fax: +61-2-9502-2556 India - Bangalore Phone: +91-80-28540800 +91-80-28540820 Fax: Indonesia - Jakarta Phone: +6221-526-7852 +6221-526-7856 Fax: Japan - Kawasaki, Kanagawa Phone: +81-44-844-8111 Fax: +81-44-812-3207 Product Information Center: (Technical Support) Phone: +81-44-844-8013 Fax: +81-44-812-3200 Raychem Products Phone: +81-44-900-5102 Fax: +81-44-5025-5027 Korea - Seoul Phone: +82-2-3415-4500 Fax: +82-2-3486-3810 Malaysia - Kuala Lumpur Phone: +60-3-78053055 Fax: +60-3-78053066 New Zealand - Auckland Phone: +64-9-634-4580 Fax: +64-9-634-4586 Philippines - Makati City Phone: +632-867-8641 Fax: +632-867-8661 People's Republic of China Hong Kong Phone: +852-2735-1628 +852-2735-0243 Fax: Shanghai Phone: Fax: +86-21-5383-8188 +86-21-5383-8018 Shunde Phone: Fax: +86-765-775-1368 +86-765-775-2823 Singapore - Singapore Phone: +65-6482-0311 Fax: +65-6482-1012 Raychem Products Phone: +65-4866-151 Fax: +65-6545-514 Taiwan - Taipei Phone: +886-2-2664-9977 Fax: +886-2-2664-9900 Thailand - Bangkok Phone: +66-2-955-0500 Fax: +66-2-955-0505 Vietnam - Ho Chi Minh City Phone: +84-8-930-5546 Fax: +84-8-930-3443 Europe/ Middle East/Africa Austria - Vienna Phone: +43-190-560-0 Fax: +43-190-560-1333 Belgium - Kessel-Lo Phone: +32-16-35-23-00 Fax: +32-16-35-23-52 Germany - Bensheim Phone: +49-6251-133-0 Fax: +49-6251-133-1600 Product Information Center: (Technical Support) Phone: +49-6251-133-1999 Fax: +49-6251-133-1988 Bulgaria - Sofia Phone: +359-2-971-2152 Fax: +359-2-971-2153 Germany - Langen Phone: +49-6103-709-0 Fax: +49-6103-709-1223 Czech Republic - Kurim Phone: +420-5-41-162-111 Fax: +420-5-41-162-223 Germany - Speyer Phone: +49-6232-30-0 Fax: +49-6232-30-2243 Denmark - Viby J Phone: +45-70-15-52-00 Fax: +45-43-44-14-14 Germany HTS Division - Neunkirchen Phone: +49-2247-305-0 Fax: +49-2247-305-122 Egypt - Cairo +20-2-417-76-47 Phone: Fax: +20-2-419-23-34 Estonia - Tallinn Phone: +372-65-05-474 +372-65-05-470 Fax: Finland - Helsinki Phone: +358-95-12-34-20 Fax: +358-95-12-34-250 France - Cergy-Pontoise Phone: +33-1-3420-8888 Fax: +33-1-3420-8600 Product Information Center: (Technical Support) +33-1-3420-8943 Phone: Fax: +33-1-3420-8623 France Tyco Electronics Export - St Ouen L'Aumone Phone: +33-1-3440-7200 Fax: +33-1-3440-7220 or +33-1-3440-7230 Great Britain - Stanmore Middlesex +44-208-954-2356 Phone: Fax: +44-208-954-8383 Product Information Center: (Technical Support) Freephone GB: 0800-267-666 Phone: +44-141 810 8967...69 +44-141 810 8971 Fax: Great Britain - Dorcan, Swindon Raychem Products Phone: +44-1793-528171 Fax: +44-1793-572516 Italy - Collegno (Torino) Phone: +39-011-4012-111 Fax: +39-011-4031-116 Lithuania - Vilnius Phone: +370-5-2131-402 Fax: +370-5-2131-403 Netherlands - 's-Hertogenbosch Phone: +31-73-6246-246 Fax: +31-73-6212-365 Product Information Center: (Technical Support) Phone: +31-73-6246-999 Fax: +31-73-6246-998 Norway - Nesbru Phone: +47-66-77-8899 Fax: +47-66-77-8855 Poland - Warsaw Phone: +48-22-45-76-700 Fax: +48-22-45-76-720 Romania - Bucharest Phone: +40-21-311-3479/3596 Fax: +40-21-312-0574 Sweden - Upplands Vasby Phone: +46-8-50-72-50-00 Fax: +46-8-50-72-50-01 Switzerland - Steinach Phone: +41-71-447-0447 Fax: +41-71-447-0444 Turkey - Istanbul Phone: +90-212-281-8181/2/3 Fax: +90-212-281-8184 Ukraine - Kiev Phone: +38-044-238-6908 Fax: +38-044-568-5740 Russia - Moscow Phone: +7-095-926-5506/07/08/09 Fax: +7-095-926-5505 Russia - St. Petersburg Phone: +7-812-118-8192 Fax: +7-812-118-8193 Greece - Athens +30-1-9370-396/397 Phone: Fax: +30-1-9370-655 Scotland - Dundee Madison Cable Products Phone: +44-1382-508080 Fax: +44-1382-505060 Hungary - Budapest +36-1-289-1000 Phone: Fax: +36-1-289-1010 Slovakia - Banska Bystrica Phone: +421-48-415-20-11/12 +421-48-415-20-13 Fax: Ireland - Dublin +353-1-820-3000 Phone: +353-1-820-9790 Fax: Slovenia - Ljubljana Phone: +386-1561-3270 +386-1561-3240 Fax: Israel - Yokneam Phone: +972-4-959-0508 +972-4-959-0506 Fax: Spain - Barcelona Phone: +34-93-291-0330 Fax: +34-93-201-7879 Product Information Center: (Technical Support): Phone: +34-93-291-0330 Fax: +34-93-200-3779 South Africa - Port Elizabeth +27-41-405-4500 Phone: +27-41-486-1314 Fax: 31 1308885-7.5M-SK-FP-3-05-87-0G3B Printed in U.S.A. Tyco Electronics Corporation www.tycoelectronics.com