Connector Assemblies 06 JUN 11 Rev C

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1 Applcaton Specfcaton Power Seres Connector Assembles 06 JUN 11 All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed, dmensons have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2. Fgures and llustratons are for dentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrements for applcaton of Power Seres 50 connector assembles n hghcurrent systems for power supples, battery chargers, telecommuncatons, and materal handlng equpment. The connector assembly conssts of a hermaphrodtc housng and two closed barrel contacts. The contacts are avalable n szes 6, 8, and and accept wre szes (AWG) that correspond to the contact sze. Reducng bushngs are avalable for contact sze 6 to accommodate smaller wre szes to a mnmum of sze 16 AWG. These contacts feature a flared wre barrel and round-ended tab. The contacts are avalable n loose-pece for termnatng wth manual or pneumatc hand-held tools and n reeled form for termnatng wth sem-automatc machnes. The housng features two contact cavtes each marked on top of the housng wth a plus (+) to ndcate postve polarty and a mnus (-) to ndcate negatve polarty. Each contact s held n the cavty by an nternal retanng sprng. The hermaphrodtc desgn of the housng ensures proper polarty n matng of the connectors. In addton, the housngs are color coded to provde vsual reference for proper matng and a molded-n mechancal key at the matng face prevents nadvertent matng of dfferent colored housngs (housngs wth same poston keys wll only engage housngs of the same color). The housng color s also coded for recommended applcaton voltage. When correspondng wth personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. Markng for Postve Polarty Housng Contact Cavtes Markng for Negatve Polarty Closed Barrel Contact Wre Barrel Reducng Bushng (for Smaller Wre Szes) Tab SYSTEM VOLTAGE (V) RECOMMENDED HOUSING COLOR Retanng Sprng Matng Face Key (Poston Vares) Retanng Sprng 12 Yellow 24 Red 36 Gray 48 Blue 80 Black Fgure Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER PRODUCT INFORMATION Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 9 LOC B

2 2. REFERENCE MATERIAL 2.1. Revson Summary Snce the prevous release of ths applcaton specfcaton, the new company logo has been appled Customer Assstance Reference Product Part Number and Product Code G802 are representatve of Power Seres 50 connector assembles. Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a local representatve or, after purchase, by callng PRODUCT INFORMATION at the number at the bottom of page Drawngs Customer Drawngs for product part numbers are avalable from the servce network. If there s a conflct between the nformaton contaned n the Customer Drawngs and ths specfcaton or wth any other techncal documentaton suppled, call PRODUCT INFORMATION at the number at the bottom of page Instructonal Materal Instructon Sheets (408-seres) provde assembly nstructons and Customer Manuals (409-seres) provde machne setup and operaton procedures. Documents avalable whch pertan to ths product are: Ratcheted Cable Cutter Hand Tool Heavy Duty Cable Cutter Hand Tool Heavy Duty Cable Cutter Hand Tool Heavy Duty Cable Cutter Hand Tool General Preventve Mantenance for Mnature Quck-Change Applcators Crmp Tool Power Seres 50 Connector Assembles Cable Strpper/Sltter Tool Handlng of Reeled Products AMP-TAPETRONIC* Machne REQUIREMENTS IMPORTANT: Usng the exact products and applcaton requrements descrbed n ths document wll ensure proper applcaton; however, to ensure relablty of performance, t s hghly recommended that an ndependent evaluaton be conducted of the chosen product combnatons (wre, connector assembles, and system) before fnal applcaton s approved Specal Assembly Consderatons and Safety These connectors MUST NOT be used for nterruptng current; otherwse, there s rsk of electrcal shock. In any case, the electrcal power supply must ALWAYS BE DISCONNECTED, and the connectors must ALWAYS BE DE-ENERGIZED (ths mght nclude dsconnectng the cable from the battery) before matng and unmatng or servcng the connectors. It s hghly recommended that these connectors not be used n external power applcatons where the electrcal potental exceeds 42 V. In applcatons where these connectors are located nternal to a devce and do not serve as the prmary means of connecton, hgh voltages are allowable. It must be determned by the orgnal equpment manufacturer (OEM) whether the connectors meet electrcal and safety requrements when used n a specfc applcaton. DANGER In applcatons where the connectors are used external to a devce or as the prmary means of dsconnectng power supples or chargng equpment, care must be taken to avod touchng exposed electrcal contacts as there s rsk of STOP electrc shock. 2 of 9

3 3.2. Lmtatons Ths product s desgned to operate n a temperature range of -20 to 105 C [-4 to 221 F] Materal The housng s made of polycarbonate, rated 94 V-0 by Underwrters Laboratores Inc. (UL). The sprngs (nsde the housng) are made of stanless steel. The contacts and reducng bushng are made of copper plated wth slver Storage A. Ultravolet Lght Prolonged exposure to ultravolet lght may deterorate the chemcal composton used n the housng materal. B. Shelf Lfe The housngs and contacts should reman n the shppng contaners untl ready for use to prevent deformaton. The housngs and contacts should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect performance. C. Chemcal Exposure Do not store housngs or contacts near any chemcal lsted below as they may cause dscoloraton of the plated fnsh of the contacts or stress corroson crackng n the housng or contact materal. Alkales Ammona Ctrates Phosphates Ctrates Sulfur Compounds Amnes Carbonates Ntrtes Sulfur Ntrtes Tartrates 3.5. Wre Selecton and Preparaton The contacts accept stranded (recommended a mnmum of 19 strands) copper wre szes 6 through 12 AWG wth a maxmum nsulaton dameter of mm [.440 n.]. Contact sze 6 can accept smaller wre szes to a mnmum of sze 16 AWG wth the use of the approprate sze reducng bushng (as descrbed n Paragraph 3.6). Wres wth less than 19 strands may be too stff and dffcult to work wth. Tarnshed copper wre must be thoroughly cleaned usng a stff wre brush, or other sutable method, that penetrates the entre bundle and cleans every conductor. The wre must be restored to a brght copper fnsh. The contact wre barrels are lned wth slver platng to assure consstently hgh conductvty whch wll be reduced f tarnshed wre s used. The wre must be cut to length. Proper strp length s necessary to properly nsert the conductors nto the contact. The strp length of the wre s shown n Fgure 2. CAUTION Reasonable care must be taken not to nck or scrape any part of the wre durng the strppng.! Fgure 2 3 of 9

4 3.6. Reducng Bushng Reducng bushngs are avalable for contact sze 6 to accommodate smaller wre szes to a mnmum of sze 16 AWG. When requred, the approprate sze reducng bushng must be nstalled onto the wre before nsertng the wre nto the contact (the reducng bushng can be nstalled onto the wre before or after strppng the wre). Placement of the reducng bushng must meet the requrements shown n Fgure 3. Placement of Reducng Bushng os Strpped Wre Ends of Conductors Must Be Vsble Wre Insulaton Must Not Enter Reducng Bushng Placement of Wre and Reducng Bushng n Contact Contact Sze 6 Wre and Reducng Bushng Must Be Straght n Relaton to Contact Wre Barrel 3.7. Crmp Requrements A. Reducng Bushng Fgure 3 If a reducng bushng s used, the reducng bushng must be held frmly nsde the contact wre barrel. The reducng bushng must be straght n relaton to the wre barrel and can protrude from the wre barrel to the dmenson provded n Fgure 4. B. Tab The contact tab must not be deformed n any way. See Fgure 4. C. Wre Barrel Crmp All conductors must be held frmly nsde the wre barrel. The crmp appled to the contact wre barrel s the most compressed area and most crtcal n ensurng optmum performance of the crmped contact. The crmped area must be symmetrcal on both sdes of the wre barrel as shown n Fgure 4. The developed crmp confguratons result from usng the specfc toolng descrbed n Secton 5, TOOLING. D. Wre Conductor and Insulaton Locaton No conductors can be folded back over the wre nsulaton. The nsulaton must not enter the wre barrel. The conductors must be vsble between the reducng bushng, f applcable, or contact wre barrel and the wre nsulaton wthn the dmenson stated n Fgure 4. 4 of 9

5 Crmp Requrements Note: Dual-ndent crmp shown. Requrements apply equally to sngle-ndent crmp. Wre Insulaton Does Not Enter Contact Wre Barrel No Loose Conductors or Conductors Folded Over Wre Insulaton Tab Not Deformed n Any Way Crmped Area Symmetrcal on Both Sdes of Wre Barrel E. Twst and Roll Fgure 4 There should be no twst or roll of the wre barrel of the crmped contact that would cause overstress or mpar usage. See Fgure 5. Crmped Porton Crmped Porton Datum Lne Fgure 5 5 of 9

6 F. Bend Allowance The force appled durng crmpng may cause some bendng between the wre barrel and wre. Such deformaton s acceptable wthn the followng lmts. 1) Up and Down -- The crmped porton must not be bent beyond the lmts shown n Fgure 6. 2) Sde-to-Sde -- The crmped porton must not be bent from one sde to the other beyond the lmts shown n Fgure 6. Note: Dual-ndent crmp shown. Requrements apply equally to sngle-ndent crmp. Up and Down Algnment Datum Lne Sde-to-Sde Algnment Datum Lne 3.8. Keyng Fgure 6 Assurance of proper matng s provded by a molded-n mechancal key at the matng face of the housng. The poston of the key of the matng housngs must be compatble. The customer drawng for the specfc housng provdes the key poston. Other key postons are avalable upon request Installng Contacts nto Housng DANGER The electrcal supply MUST BE DISCONNECTED and the connectors MUST BE DE-ENERGIZED (ths mght nclude dsconnectng the cable from the battery) before nstallng the contacts nto the housng. STOP The contacts must NOT be forced nto the housng. Each contact must be nstalled n the housng accordng to the followng requrements. 1. Each contact must be nserted nto the wre sde of the housng. 2. The bottom of each contact must face the retenton sprng of the housng. 3. Each contact must be n straght algnment wth the contact cavty. 4. Each contact must be fully latched onto the housng retanng sprng Removng Contacts from Housng The housng retenton sprng must be depressed away from the undersde of the contact to remove the contact from the housng. A contact must be removed from the housng accordng to the followng: 6 of 9

7 DANGER The electrcal supply MUST BE DISCONNECTED and the connectors MUST BE DE-ENERGIZED (ths mght nclude dsconnectng the cable from the battery) before removng the contacts from the housng. STOP Secton 5 lsts avalable extracton tools used to remove these contacts. 1. The tp of the tool must be nserted between the sdes of contact and the contact cavty at the matng face of the housng. 2. The handle of the tool must be pushed down so that the housng retenton sprng s depressed away from the undersde of the contact. Whle holdng the tool n poston, the wre must be pushed down and gently pulled back untl the contact s free from the housng Matng and Unmatng Connectors DANGER The electrcal supply MUST BE DISCONNECTED and the connectors MUST BE DE-ENERGIZED (ths mght nclude dsconnectng the cable from the battery) before matng or unmatng the connectors. STOP The connectors must NOT be forced to mate or unmate. When fully mated, the housngs must appear flush at the pont of engagement Repar The contact, housng, and reducng busng are not reparable. Damaged or defectve contacts, housngs, or reducng bushngs must not be used. The contacts or reducng bushngs must not be re-used by removng the wre. 4. QUALIFICATION Power Seres 50 connector assembles are Component Recognzed by Underwrters Laboratores Inc. (UL) n Fle E28476 and have been Investgated to CSA Internatonal Standards by UL. 5. TOOLING Toolng part numbers and nstructonal materal packaged wth the toolng are shown n Fgure Cable Cutters These cable cutters are avalable for cuttng the cable to length Hand Tools Hand tools for manual applcaton of loose pece contacts are avalable to cover the full wre sze range. Industry standard toolng for manual applcaton of loose pece contacts s avalable for the full wre sze range. Recommended manufacturer and toolng descrpton and part numbers are gven n Fgure 7. Consult manufacturer's lterature for nformaton on usng the toolng Power Unt A sem-automatc machne for power asssted applcaton of tape and reeled contacts are avalable for the full wre sze range. The machne s desgned to be used as stand-alone bench unt Extracton Tool The extracton tool or a standard nsulated screwdrver wth 1/4-n. flat blade must be used to remove contacts from the housng. 7 of 9

8 5.5. Strppng Tool The cable strpper s used to strp nsulaton from the cable. Heavy Duty Cable Cutter Hand Tool ( ) Heavy Duty Cable Cutter Hand Tool ( ) Heavy Duty Cable Cutter Hand Tool ( ) Ratcheted Cable Cutter Hand Tool ( ) Crmp Tool ( ) Standard Insulated Screwdrver Wth 1/4-n. Flat Blade Cable Strpper/Sltter Tool ( ) Extracton Tool (No Document) Commercally Avalable Pneumatc Hand Crmpng Tool, De Set, and Locator (Dual- Indent Crmp) AMP-TAPETRONIC Machne ( ) Avalable from Pacfc Industral Components (PICO) Camarllo, CA (805) ( (See Table) SERIES DIE SET LOCATOR DIE CLOSURE FOR CONTACT SIZE 6 and DA DA DA DA n..134 n. Fgure 7 8 of 9

9 6. VISUAL AID Fgure 8 shows a typcal applcaton of Power Seres 50 connector assembles. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. FIGURE 8. VISUAL AID 9 of 9

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