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