Application Specification 114-13127 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 15 JAN 09 Rev B All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and NOTE _ inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2 . i 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 15, 30, and 45 (single-pole) connector assemblies used in high-current systems for office furniture, power supplies, battery chargers, telecommunications, and material handling equipment. Each connector assembly consists of a housing and an open-barrel barrel (cold-headed) or closed-barrel (stamped-and-formed) contact. Accessories available for the connector assemblies are a cable clamp kit, spiral retainer pin, spacer (short and long), mounting wing, mounting clamp, plug frame (with latches and without latches), and panel mount frame. 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. Housing Contact Stop (Inside) Contacts Open-Barrel Hood Stabilizer Dovetail Retaining (4 Places) Spring (Inside) Wire Barrel Tab Wire Stop Cable End Mating Face Tongue Contact Cavity Closed-Barrel Blade Half Round Wire Barrel Blade (2 Places) Accessories Cable Clamp Kit Spiral Short Spacer Mounting Clamp Long Spacer Mounting Wing (For 3 Stacked Housings Retainer Pin Shown) Mounting Hole Screw (2 Included) Cable Clamp Spiral Retainer Pin Holes Plug Frame Dovetail With Latches (2 Places) Mounting Latch (2 Places) Spiral Retainer Hole Pin Hole Plug Frame Mounting Latch Without Latches Panel Mount Frame (2 Places) Latching Tab Mounting (2 Places) Flange Cable End Cable End Figure 1 E 2009 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 22 LOC B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 These connectors are designed for free-hanging, surface mount, and panel mount applications. 1.1. Features The housing features a contact cavity, dovetails, and half rounds. The contact cavity has an internal retaining spring that retains the contact in the housing. The housings can be joined with other housings on all four sides using the dovetails. The hermaphroditic design of the housing ensures proper polarity in mating. The housings are color coded to provide visual reference for proper mating of the connectors. The open-barrel contact features a wire barrel, blade, and stabilizer tab. When the contact is inserted into the housing, the stabilizer tab ensures proper insertion depth for the blade to engage the internal retaining spring. These contacts are available in reeled form for terminating with a semi-automatic machine and loose piece form for terminating with a manual hand tool. The closed-barrel contact features a wire barrel, blade, and wire stop. When the contact is inserted into the housing, the wire stop ensures proper insertion depth for the blade to engage the internal retaining spring. These contacts are available in loose-piece form for terminating with a manual hand tool. 1.2. Accessories A. Cable Clamp Kit The cable clamp kit consists of a cable clamp and two screws. The kit is designed to be installed onto the the plug frame to provide strain relief for the cable. The kit is available for 4-, 6-, and 8-pole (number of stacked housings) plug frames. B. Spiral Retainer Pin The spiral retainer pin is used to hold stacked housings together or retain the stacked housings in the frame. The spiral retainer pin is available in three lengths: 6.35 [.25] (short; for use in a single row of housings), 11.18 [.44] (medium; for use in a double row of housings), and 21.6 [.85] (long; for use in a frame). C. Spacer The spacer is available in short and long. The short spacer is used to fill voids in an uneven amount of stacked housings, and the long spacer is used in conjunction with the short spacer to create polarized keying. The spacers are color coded to provide visual reference for matching corresponding spacers. D. Mounting Wing The mounting wing is used to mount housings onto a surface. The mounting wing features dovetails that are used to interlock the housings and adjacent mounting wings. The mounting wing must be secured to the surface using commercially available hardware. E. Mounting Clamp The mounting clamp is used to mount housings onto a panel. The mounting clamp is secured to the panel using commercially available hardware. F. Frames The frames--plug with latches, plug without latches, and panel mount--accommodate 2 to 8 housings (a double row with a maximum of 4 housings). The frames are used for orderly cable management. The integral latches and latching tabs prevent accidental disconnection of mated connectors. The plug frame with latches mates with the plug without latches for free-hanging applications or with the panel mount frame for panel mount applications. 2 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 2. REFERENCE MATERIAL 2.1. Revision Summary Revisions to this application specification include: S S S S S Updated document to corporate requirements Changed product code in Paragraph 2.2 Changed nomenclature for contacts Added text to Paragraph 3.9 Added document reference for extraction tool and changed part number for Model "K" terminating machine in Figure 20 2.2. Customer Assistance Reference Product Part Number 1604116 and Product Code H300 are representative of Power Series 15, 30, and 45 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 product assembly instructions or tooling setup and operation procedures and Customer Manuals (409-series) provide machine setup and operation procedures. Documents available which pertain to this product are: 408-8040 Heavy Duty Miniature Quick-Change Side Feed Applicator 409-5128 AMP-O-LECTRIC* Model "K" Terminating Machine 409-5842 AMP-O-LECTRIC Model "G" Terminating Machine 354500-1 3. REQUIREMENTS 3.1. Material The housing, mounting wing, and spacer are made of polycarbonate, rated 94 V-0 by Underwriter Laboratories, Inc. (UL). The contacts are made of copper plated with silver or tin. The spiral retainer pin is made of stainless steel. 3.2. 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 Amines Rev B Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Tyco Electronics Corporation Sulfur Compounds Tartrates 3 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.3. Cable Selection and Preparation The contacts accept stranded copper cable sizes 20 through 10 AWG with a minimum of 19 wire strands and a maximum insulation diameter of 18.16 [.175]. NOTE Cable with less than 19 wire strands must not be used. Cable with less than 19 wire strands is too stiff and could cause the contact to twist inside the housing when dressing the cable. i The cable must be cut to length. Proper strip length is necessary to properly insert the wires into the contact. The strip length of the cable is shown in Figure 2. CAUTION Reasonable care must be taken not to nick or scrape any part of the cable during the stripping. ! Recommended Cable Strip Length Strip Length (Refer to Table) Note: Not to Scale CABLE STRIP LENGTH CONNECTOR CABLE SIZE SERIES RANGE (AWG) 20-16 Open-Barrel Closed-Barrel Contact Contact 4.30-6.48 [.170-.255] 15 18-16 16-12 4.30-6.48 [.170-.255] 7.87-8.89 [.309-.350] 30 14-12 45 14-10 5.71-6.98 [.225-.275] 7.87-8.89 [.309-.350] Figure 2 3.4. Crimp Requirements The following crimp requirements result from using the tooling described in Section 5. A. Open-Barrel Contact Using Semi-Automatic Machine The crimped open-barrel contact using the semi-automatic machines must meet the requirements given in Figure 3. The cutoff tab is the remaining portion of the carrier strip after the contact is cut from the strip. The cutoff tab and the burr resulting from the cutoff tab shearing must not exceed the dimension given in Figure 3 (Detail). All cable wires must be held firmly inside the wire barrel. The crimp applied to the 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. The crimp height and width must be within the dimensions provided in Figure 3. 4 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 Open-Barrel Contact Crimp Requirements Using Semi-Automatic Machines 2.47 [.097] Max 0.75 [.03] Max Wires Visible Between Wire Barrel and Rear Bellmouth Height Cable Insulation End of Wires Flush With or Extends No More Cable Insulation Does Not Enter Than 2.54 [.100] from End of Wire Barrel Wire Barrel (Allowed to Butt Against Wire Barrel) X Blade Not Deformed in Any Way X Stabilizer Tab Not Deformed in Any Way All Wires Held Firmly in Wire Barrel No Wires Folded Back Over Wire Insulation Wire Barrel Seam Completely Closed Cutoff Tab (2 Places) with No Evidence of Loose Wire Strands See Detail or Wire Strands Visible in Seam No Front Bellmouth Crimp is Symmetrical on Both Sides of Wire Barrel 4.06 [.16] Max Rear Bellmouth Width Section X-X Detail Wire Barrel Crimp 0.2 [.008] Max Burr Width (See Table) 0.4 [.016] Max Cutoff Tab 0.26 [.010] Max Flash Wire Barrel Crimp Height (Extruded Cable Insulation) (Not Including Flash) (See Table) CONNECTOR CABLE SIZE CRIMP HEIGHT CRIMP WIDTH SERIES (AWG) +0.08 [+.003] +0.08 [+.003] 20 1.50 [.059] 18 1.63 [.064] 16 1.75 [.069] 16 1.96 [.077] 14 2.13 [.084] 12 2.39 [.094] 14 2.44 [.096] 12 2.67 [.105] 10 2.95 [.116] 15 30 45 3.05 [.120] 3.56 [.140] 3.94 [.155] Figure 3 Rev B Tyco Electronics Corporation 5 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 B. Open-Barrel Contact Using Hand Tool The crimped open-barrel contact using the hand tool must meet the requirements given in Figure 4. The crimp applied to the wire barrel is the most compressed area and most critical in ensuring optimum performance of the crimped contact. The crimp height and width must be within the dimensions provided in Figure 4. Open-Barrel Contact Crimp Requirements Using Hand Tool 2.47 [.097] Max Crimp Height (See Table) Measure Here Wires Visible Between Wire Barrel and Cable Insulation Cable Insulation Does Not Enter End of Wires Flush with Wire Barrel or Wire Barrel (Allowed to Butt Extends No More Than 2.47 [.097] from Against Wire Barrel) End of Wire Barrel Blade Not Deformed in Any Way Stabilizer Tab Not No Wires Folded Back Deformed in Any Way Over Cable Insulation Wire Barrel Seam Completely Closed with No Evidence of Loose Wire Strands All Wires Held Firmly in Wire Barrel or Wire Strands Visible in Seam Crimp is Symmetrical on Both Sides of Wire Barrel CLOSED-BARREL CONTACT CONNECTOR CABLE SIZE SERIES (AWG) 45 10 CRIMP HEIGHT CRIMP WIDTH +0.08 [+.003] +0.08 [+.003] 3.12 [.123] 4.47 [.176] Figure 4 6 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 C. Closed-Barrel Contact Using Hand Tool When placing the closed-barrel contact in the tool, it is important to make sure that the contact is not positioned upside-down. The contact must be positioned in the tool with the seam of the wire barrel facing squarely toward the upper die. See Figure 5. The crimped closed-barrel contact using the hand tool must meet the requirements given in Figure 5. The crimp applied to the wire barrel is the most compressed area and most critical in ensuring optimum performance of the crimped contact. The crimp height and width must be within the dimensions provided in Figure 5. Proper Position of Closed-Barrel Contact in Hand Tool Seam of Wire Barrel Upper Die (For Clarity, Tool Not Shown) Closed-Barrel Contact Crimp Requirements Using Hand Tool 2.47 [.097] Max Wires Visible Between Wire Barrel and Cable Insulation Crimp Height (See Table) Slight Deformation of Measure Here Cable Insulation Does Not Enter Wire Barrel (Allowed to Butt Wire Stop is Acceptable Against Wire Barrel) Blade Not Deformed in Any Way End of Wires Butt No Wires Folded Back Against Wire Stop Over Cable Insulation Wire Barrel Seam Completely Closed with No Evidence of Loose Wire Strands All Wires Held Firmly in or Wire Strands Visible in Seam Wire Barrel Crimp is Symmetrical on Both Sides of Wire Barrel CLOSED-BARREL CONTACT CONNECTOR CABLE SIZE SERIES RANGE (AWG) CRIMP HEIGHT CRIMP WIDTH +0.08 [+.003] +0.08 [+.003] 15 14-12 1.83 [.072] 3.23 [.127] 30 18-16 1.96 [.077] 3.56 [.140] Figure 5 Rev B Tyco Electronics Corporation 7 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.5. 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 6. Avoid Twist and Roll Open-Barrel Contact Closed-Barrel Contact End of Wires Wire Barrel Wire Barrel Datum Line End of Wires Datum Line Stabilizer Blade Tab Wire Stop Blade Blade (Reference Point) (Reference Point) Blade Figure 6 3.6. Bend Allowance The force applied during crimping may cause some bending between the wire barrel and cable. Such deformation is acceptable within the following limits. 1. Up and down -- the contact must not be bent beyond the limits shown in Figure 7. 2. Side-to-side -- the crimped portion of the contact must not be bent from one side to the other. Open-Barrel Contact _ Max 5 Up and Down Bend Datum Line _ Max 5 _ Max 3 Side-to-Side Bend Datum Line _ Max 3 Closed-Barrel Contact _ Max 5 Up and Down Bend Datum Line _ Max 5 _ Max 3 Side-to-Side Bend Datum Line _ Max 3 8 of 22 Figure 7 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.7. Special Assembly Considerations -- For optimum results, it is recommended intermating housings containing contacts with the same plating (tin to tin or silver to silver). -- DO NOT restrict movement of the contacts that would affect their performance (such as bending unsupported cables). -- DO NOT restrict heat dissipation from the connectors. 3.8. Installing Contact into Housing A contact must be inserted into the cable end of the housing with the bottom of the contact facing the retaining spring of the housing. The contacts MUST NOT be forced into the housing. The installed contact must meet the requirements given in Figure 8. Installing Contact into Housing Closed-Barrel Contact Shown, Same Requirements Apply to Open-Barrel Contact Hood (Ref) Bottom of Contact Retaining Spring Cable End of Housing of Housing Requirements of Installed Contact (Cross-Section) Open-Barrel Contact Stabilizer Tab is Against Cable is Straight in Housing Contact Stop Relation to Housing Contact Blade is Fully Latched onto Retaining Spring of Housing Closed-Barrel Contact Contact Wire Stop is Against Housing Contact Stop Cable is Straight in Relation to Housing Contact Blade is Fully Latched onto Retaining Spring of Housing Figure 8 Rev B Tyco Electronics Corporation 9 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.9. Stacking Housings and Installing Spiral Retainer Pins The housings must be interlocked using the dovetails. A housing must be slid onto another housing from the mating face of the housings until the dovetails are engaged, the ends of the housings are flush, and the half rounds of the housings form a hole. Refer to Figure 9, Detail A. The housings can be stacked in a vertical, horizontal, or block configuration. A spiral retainer pin--using a short for horizontal and a medium for block--should be inserted into the formed hole to hold the stacked housings together. When seated, the spiral retainer pin must be flush with the top and bottom of the stacked housings. One spiral retainer pin should be installed into each formed hole. For 2 vertical stacked housings, one retainer pin should be inserted into one of the formed half holes. See Figure 9, Detail B. CAUTION Commercially available roll pins MUST NOT be used. Roll pins could fall out of the housings and cause damage to the system. ! Stacked housings can be permanently bonded by applying a small drop of cyanoacrylate glue to the joint between the dovetails. Stacking Housings Detail A Detail B Spiral Retainer Pin (Optional) Formed Hole Mating Face of Housings Vertical Horizontal Block Joint Between Dovetails Figure 9 Standard direct current (DC) connectors recommended by the Radio Amateur Civil Emergency Service (RACES) must be stacked as shown in Figure 10. Red (as positive) and black (as negative) are the recommended housing colors. RACES Recommended Standard DC Connectors Red (Positive) Housing Hood Black (Negative) Tongue Housing Figure 10 10 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.10. Installing Spacer When stacking an uneven amount of housings, a short spacer must be used to fill the void(s). If keying is desired, a short spacer must be used in one stack and a long spacer must be used in the mating stack. The spacers must be installed in corresponding positions of the mating housings. Refer to Figure 11. The housings and spacers must be interlocked using the dovetails. The half rounds of the housings and spacers must form a hole. Installing Spacer Mating 3 Stacked Connectors Shown Spiral Retainer Pin (Ref, Optional) Spiral Retainer Pin Long (Ref, Optional) Spacer Short Spacer Figure 11 3.11. Installing Plug Frame, Panel Mount Frame, and Spiral Retainer Pins Stacked housings to be installed into a frame must not contain any spiral retainer pins. The cable of the stacked housings must be fed through the mating face of the frame until the housings are seated in the frame. A long spiral retainer pin must be used to retain the stacked housings (and if used, spacers) in the frame. Exploded view is shown in Figure 12. The spiral retainer pin must be installed through a spiral retainer pin hole in the frame and into the formed hole of the stacked housings (and if used, spacers). When seated, the spiral retainer pin must be flush with the top and bottom of the frame. One spiral retainer pin should be installed for each formed hole of the stacked housings. CAUTION Commercially available roll pins MUST NOT BE USED. Roll pins could fall out of the frame and cause damage to the system. ! Spiral retainer pins must be installed in compatible hole positions for the mating frames. To ensure compatibility, there must be two empty holes between the spiral retainer pins of mated frames. Compatible hole positions are given in Figure 12. Spiral retainer pins installed in incompatible hole positions prevent the connectors from mating. This arrangement could be used for keying purposes or to prevent the energized side of the connection from accidental exposure to a shorting object. 3.12. Installing Cable Clamp Kit The cable clamp must be installed over the cable and onto the plug frame so that the ends of the cable clamp are flat against the frame. The cable must not be pinched. The screws must be secure. An exploded view is shown in Figure 12. CAUTION To avoid damage to the frame, screws must not be over-tightened. ! Rev B Tyco Electronics Corporation 11 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 Installing Plug Frame (Exploded View) Plug Frame With Latches Shown, Same Requirements Apply to Plug Frame Without Latches 4 Stacked Connectors Spiral Retainer Pin (Ref) Screws Cable Clamp Mating Face 4-Pole Plug Frame (Ref) Installing Panel Mount Frame (Exploded View) 4 Stacked Connectors Spiral Retainer Pin (Ref) 4-Pole Panel Mount Frame (Ref) Mating Face Compatible Hole Positions of Spiral Retainer Pins for Mating Frames H is Hole, P is Spiral Retainer Pin Plug Frame With Latches Housing Plug Frame Without Latches -Or- Panel Mount Frame Housing Figure 12 12 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.13. Panel Cutout The panel thickness range shall be 0.76 through 3.40 [.030 through .134]. The panel must be cut using the dimensions provided in Figure 13. Through Surface Mount Panel Cutout for Surface Mounting Mounting Wings Vertical or Surface Mount 23.21 [.914] 23.21 [.914] 4.5 [.178] 16.21 [.638] 4.5 [.178] 8.92 [.351] Number of Housings and If Used, Spacers ( Note: Not to Scale 15.71 [.6185]) + 0.5 [.019] Panel Cutout for Panel Mounting Mounting Clamps Single Row Double Row 8.64 [.34] 3.96 [.156] 12.7 [.50] 3.96 [.156] (2 Places) (2 Places) 17.27 [.680] 16.31 [.642] 25.4 [1.000] 8.41 [.331] A Panel Mount Frame A B 25.4 [1.00] TOTAL NUMBER OF HOUSINGS AND SPACERS DIMENSION Single Row Double Row A B 2 4 16.31 [.642] 31.75 [1.25] 3 6 24.21 [.953] 41.15 [1.62] 4 8 32.11 [1.264] 47.75 [1.88] Figure 13 Rev B Tyco Electronics Corporation 13 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.14. Surface Mounting Two mounting wings--one on each side of a housing or stacked housings--and commercially-available hardware (two No. 6 pan head screws and nuts) are required to mount housings onto the surface. The length of the screws must be determined by measuring the thickness of the surface, mounting wing, and nut. Mounting wings can be used with up to 8 stacked housings. Spacers must be used with an uneven amount of stacked housings. The mounting wings are designed to provide sufficient support for NO MORE than 8 stacked housings. Each mounting wing must be installed onto the housing from the mating face of the housings so that the dovetails engage, and the end of mounting wings are even with the housings. Refer to Figure 14. Installing Mounting Wings Mounting Wing 2 Stacked Even with Housings Connectors (Ref) Dovetails Are Engaged Mounting Wing Mating Face of Housings Figure 14 The housings can be mounted onto the front or back of the surface with the housings through the surface, on the surface, or vertical to the surface. To ensure proper mating, care must be used to avoid interference between adjacent mounted housings and other components. When installed, the mounting wings must be fully seated on the panel and the hardware secure. See Figure 15. Surface Mounting 3 Stacked Connectors Shown, Same Requirements Apply to All Others Through Surface Mount 8-32 Nut Vertical Surface Mount 8-32 Screw Cable (2 Places) Mounting Wing (2 Places) Housing (2 Places) Mounting Wing (2 Places) Cable Surface Surface 8-32 Screw 8-32 Nut (2 Places) (2 Places) Housing Surface Mount 8-32 Screw Housing (2 Places) Mounting Wing (2 Places) Surface 8-32 Nut Cable (2 Places) Figure 15 14 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.15. Panel Mounting A. Using Mounting Clamp Two mounting clamps--one on top and one on bottom of the stacked housings--and commercially- available hardware (two No. 6 pan head screws and nuts) are required to mount housings onto the panel. The length of the screws must be determined by measuring the thickness of the panel, mounting clamp, and nut. The mounting clamps are designed to be used with housings not containing spiral retainer pins. The mounting clamp is available for up to 8 stacked housings. When installed, the mounting clamp must be flat against the panel and the hardware secure. Dimensions for clearance are given in Figure 16. Panel Mounting Using Mounting Clamps Single Row Double Row Screw Mounting Clamp Screw (2 Places) (2 Places) Mounting Clamp Panel Panel (2 Places) (2 Places) 27.94 [1.1] 3 Stacked 35.56 [1.4] 6 Stacked Connectors Connectors (Ref) (Ref) A A Note: Not to Scale NUMBER OF HOUSINGS AND, IF USED, SPACERS DIMENSION A Single Row Double Row 2 4 22.85 [.9] 3 6 33.02 [1.3] 4 8 40.64 [1.6] Figure 16 B. Using Panel Mount Frame The panel mount frame is designed to be be front panel mounted. The mounting flange of the panel mount frame must be flat against the panel. See Figure 17. Panel Mounting Using Panel Mount Frame Front of Panel Cable 4 Stacked Connectors (Ref) Mating Face Mounting Flange is Flat Against Panel Figure 17 Rev B Tyco Electronics Corporation 15 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 3.16. Mating A. Housings Housings must be slid together until there is no gap between the hood of the housing and the mated housing. Refer to Figure 18. Mating Housings Free-Hanging Housings Shown, Same Requirements Apply to Surface-Mounted and Panel-Mounted Housings There Is No Gap Between Hood of Housing and Mated Housing Figure 18 B. Frames The mating faces of the plug frames must be aligned, then pushed together until the latch engages the latching tab. Refer to Figure 19. NOTE Spiral retainer pins located in incompatible hole positions will prevent frames from latching. i Mating Frames Plug Frame With Latches Mated to Plug Frame Without Latches Shown Same Requirements Apply to Panel Mount Frame (Top View) Latch (Plug Frame With Latches) Latching Tab (Plug Frame Without Latches) Figure 19 3.17. Strain Relief When bending or forming cable, the bundle must be held at least 6.35 [.250] beyond the back of the housing or frame before bending in any direction. For mated housings, if the installation is to be subject to bending forces, strain relief should be provided on the cable bundle approximately 25.4 [1.0] from the back of the housing. 16 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies CAUTION 114-13127 Unsupported cable must not be bent as this may cause strain on the contacts inside the housing. ! 3.18. Disassembly A. Unmating Housings and Extracting Contact If used, the spiral retainer pin must be removed (the pin must be pushed through the formed hole of the housings until exposed, then pulled out of the opposite side). The housings must be unmated by grasping the housings and pulling them straight apart. DO NOT disconnect under load (not for interrupting current). CAUTION To avoid personal injury, electrical supply MUST BE DISCONNECTED BEFORE unmating housings. ! Contacts must be extracted by inserting the tip of the tool into the front of the housing, depressing the retaining spring toward the tongue of the housing, then grasping the cable, the contact can be pulled straight out of the housing (refer to Section 5 for description of tooling). B. Accessories The frames must be unmated by depressing the latches of the plug frame, then pulling the frames straight apart. The accessories must be disassembled in the following order: Plug Frame -- 1) remove cable clamp, 2) remove spiral retainer pin(s): each pin must be pushed through the hole of frame until exposed, then pulled out of the opposite side, 3) remove housings: the cable must be pushed until the housing stack is out of the frame. Panel Mount Frame -- 1) remove frame from panel: mounting latches must be depressed, then the frame can be pushed through the panel, 2) remove spiral retainer pin(s): each pin must be pushed through the hole of the frame until exposed, then pulled out of the opposite side, 3) remove housings: the cable must be pushed until the housing stack is out of the frame. 3.19. Repair Damaged or defective connectors, contacts, or accessories MUST NOT be used. Contacts MUST NOT be re-used by removing the cable. 4. QUALIFICATION Power Series 15, 30, or 45 connector assemblies are Component Recognized by Underwriter Laboratories, Inc. (UL) under 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 given in Figure 20. 5.1. Extraction Tool The extraction tool or a standard insulated screwdriver with a 1/8-in. or 2-mm flat blade must be used to remove a contact from the housing. 5.2. Hand Tool Commercially-available hand tools for manual application of loose-piece contacts are available. It is recommended using the PWRcrimp powerpole crimp tool from West Mountain Radio (http://www.westmountainradio.com). This hand tool should be used for field repair only. NOTE Consult manufacturer's literature for information on using the tool. i Rev B Tyco Electronics Corporation 17 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 5.3. Applicators The applicators are designed to crimp reeled open-barrel contacts onto pre-stripped cable. Crimping dies are included with the applicator. 5.4. Semi-Automatic Machines The machines provide the force required to drive the applicator. These machines are designed to be bench mounted and are operated by a foot pedal. These machines provide for high volume, heavy duty production requirements. Loose-Piece Open-Barrel and Closed-Barrel Contacts Extraction Tool 68265-1 (Refer to 408-2597) PWRcrimp Powerpole Crimp Tool or Standard Insulated Screwdriver With (Available from West Mountain Radio) 1 /8-in. or 2-mm Flat Blade CABLE SIZE RANGE CONNECTOR (AWG) SERIES 14-12 15 18-16 30 10 45 CONTACT TYPE Closed Barrel Open Barrel Strip Form Open-Barrel Contact AMP-O-LECTRIC Model G" AMP-O-LECTRIC Model K" Heavy Duty Miniature Quick-Change Terminating Machine 354500-1 Terminating Machine Side Feed Applicator (Refer to Table) (409-5842) 2-565435-2 (409-5128) (408-8040) CABLE SIZE RANGE (AWG) CONNECTOR SERIES APPLICATOR 20-16 15 1385450-3 16-12 30 1385468-3 14-10 45 1385469-3 Figure 20 18 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 6. VISUAL AID The illustration below shows a typical application of Power Series 15, 30, and 45 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. CRIMPED CONTACT OPEN-BARREL CONTACT WIRE BARREL SEAM MUST BE COMPLETELY CLOSED (Using Semi-Automatic Machine) WITH NO EVIDENCE OF LOOSE WIRE STRANDS OR WIRE STRANDS VISIBLE IN SEAM END OF WIRES MUST BE FLUSH BLADE MUST NOT ALL WIRES MUST BE HELD WITH OR EXTEND SLIGHTLY BE DEFORMED IN BEYOND WIRE BARREL ANY WAY FIRMLY IN WIRE BARREL REAR BELLMOUTH MUST BE VISIBLE WIRES MUST BE VISIBLE BETWEEN WIRE BARREL AND CABLE INSULATION STABILIZER TAB MUST BE NOT DEFORMED IN ANY WAY THERE MUST BE NO WIRES FOLDED BACK OVER CABLE INSULATION CRIMP MUST BE SYMMETRICAL ON BOTH SIDES OF WIRE BARREL FOR STRIP FORM CONTACTS, CUTOFF TAB AND BURR MUST NOT CABLE INSULATION MUST NOT ENTER EXCEED REQUIRED DIMENSIONS WIRE BARREL, HOWEVER MAY BUTT AGAINST WIRE BARREL CLOSED-BARREL CONTACT ALL WIRES MUST BE HELD FIRMLY IN WIRE BARREL WIRES MUST BE VISIBLE BETWEEN WIRE BARREL AND CABLE INSULATION WIRE BARREL SEAM MUST BE THERE MUST BE NO WIRES FOLDED BACK COMPLETELY CLOSED WITH NO OVER CABLE INSULATION EVIDENCE OF LOOSE WIRE STRANDS OR WIRE STRANDS VISIBLE IN SEAM END OF WIRES MUST BUTT CABLE INSULATION MUST NOT ENTER AGAINST WIRE STOP WIRE BARREL, HOWEVER MAY BUTT AGAINST WIRE BARREL WIRE STOP CAN BE FOR STRIP FORM CONTACTS, SLIGHTLY DEFORMED CUTOFF TAB AND BURR MUST NOT EXCEED REQUIRED DIMENSIONS CRIMP MUST BE BLADE MUST NOT SYMMETRICAL ON BOTH BE DEFORMED IN SIDES OF WIRE BARREL ANY WAY FIGURE 21. VISUAL AID (CONT'D) Rev B Tyco Electronics Corporation 19 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 FREE-HANGING APPLICATION HOUSING MATED TO HOUSING CABLE MUST BE STRAIGHT THERE MUST BE NO GAP IN RELATION TO HOUSING BETWEEN HOOD OF HOUSING AND MATED HOUSING FOR STACKED HOUSINGS, EACH FORMED HOLE SHOULD CONTAIN A SPIRAL RETAINER PIN EACH CONTACT BLADE MUST BE FULLY LATCHED ONTO FOR STACKED HOUSINGS, RETAINING SPRING OF HOUSING IF USED, SPIRAL RETAINER PIN MUST BE FLUSH WITH TOP AND BOTTOM OF HOUSINGS HOUSINGS MUST NOT BE DAMAGED IN ANY WAY PLUG FRAME WITH LATCHES MATED TO PLUG FRAME WITHOUT LATCHES FRAMES MUST NOT BE DAMAGED IN ANY WAY ONE SPIRAL RETAINER PIN HOLE OF FRAME MUST CONTAIN A SPIRAL RETAINER PIN FOR EACH FORMED HOLE OF STACKED HOUSINGS SPIRAL RETAINER PIN(S) MUST BE FLUSH WITH TOP AND BOTTOM OF FRAME LATCHES MUST BE ENGAGED HARDWARE MUST TO LATCHING TABS BE SECURE ENDS OF CABLE CLAMP MUST BE FLAT AGAINST FRAME CABLE MUST NOT BE PINCHED FIGURE 21. VISUAL AID (CONT'D) 20 of 22 Tyco Electronics Corporation Rev B Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 SURFACE MOUNT APPLICATION MOUNTING WINGS MOUNTING WINGS MUST NOT BE DAMAGED IN ANY WAY END OF MOUNTING WINGS MUST BE EVEN WITH HOUSINGS HOUSINGS AND MOUNTING WINGS MUST BE FULLY HARDWARE MUST SEATED ON SURFACE BE SECURE HOUSING MATED TO HOUSING ALSO APPLY REQUIREMENTS FOR PANEL MOUNT APPLICATION MOUNTING CLAMP HARDWARE MUST BE SECURE HOUSINGS ARE SHOWN UNMATED FOR CLARITY OF HOUSING ORIENTATION (WHEN MATED, HOUSINGS MATED TO HOUSING ALSO APPLY) REQUIREMENTS FOR MOUNTING CLAMP MUST BE FLAT AGAINST PANEL FIGURE 21. VISUAL AID (CONT'D) Rev B Tyco Electronics Corporation 21 of 22 Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127 PLUG FRAME WITH LATCHES MATED TO PANEL MOUNT FRAME ONE SPIRAL RETAINER PIN HOLE OF FRAME MUST CONTAIN A SPIRAL RETAINER PIN FOR EACH FORMED HOLE OF STACKED HOUSINGS SPIRAL RETAINER PIN(S) MUST BE FLUSH WITH TOP AND BOTTOM OF FRAME HARDWARE MUST MOUNTING FLANGE MUST BE SECURE BE FLAT AGAINST PANEL ENDS OF CABLE CLAMP MUST BE FLAT AGAINST LATCHES MUST BE ENGAGED FRAME TO LATCHING TABS CABLE MUST NOT BE PINCHED FRAMES MUST NOT BE DAMAGED IN ANY WAY FIGURE 21. VISUAL AID (END) 22 of 22 Tyco Electronics Corporation Rev B