1445716-8 - Tyco Electronics

Figure 1

Housing Closed Barrel Contact Reducing Bushing

(For Smaller Wire Sizes)

Key (Position

Varies)

Mating

Face

Tab

Contact Cavities

Marking for

Positive Polarity

Marking for

Negative Polarity

Wire

Barrel

Retaining

Spring

Retaining

Spring

Note: Other color codes and voltage ratings are available upon request.

Application Specification

Power Series 50 114--13071

LOC B

1of 9

E2010 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1--800--722--1111

PRODUCT INFORMATION 1--800--522--6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.tycoelectronics.com

Connector Assemblies 02 FEB 10 Rev B

All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and

inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2_.

Figures and illustrations are for identification only and are not drawn to scale.

1. INTRODUCTION

This specification covers the requirements for application of Power Series 50 connector assemblies in

high--current systems for power supplies, battery chargers, telecommunications, and material handling

equipment. The connector assembly consists of a hermaphroditic housing and two closed barrel contacts.

The contacts are available in sizes 6, 8, and 10--12 and accept wire sizes (AWG) that correspond to the

contact size. Reducing bushings are available for contact size 6 to accommodate smaller wire sizes to a

minimum of size 16 AWG. These contacts feature a flared wire barrel and round--ended tab. The contacts are

available in loose--piece for terminating with manual or pneumatic hand--held tools and in reeled form for

terminating with semi--automatic machines.

The housing features two contact cavities each marked on top of the housing with a plus (+) to indicate positive

polarity and a minus (--) to indicate negative polarity. Each contact is held in the cavity by an internal retaining

spring. The hermaphroditic design of the housing ensures proper polarity in mating of the connectors. In

addition, the housings are color coded to provide visual reference for proper mating and a molded--in

mechanical key at the mating face prevents inadvertent mating of different colored housings (housings with

same position keys will only engage housings of the same color). The housing color is also coded for

recommended application voltage.

When corresponding with personnel, use the terminology provided in this specification to facilitate your

inquiries for information. Basic terms and features of this product are provided in Figure 1.

SYSTEM VOLTAGE (V) RECOMMENDED

HOUSING COLOR

12 Yellow

24 Red

36 Gray

48 Blue

80 Black

NOTE

Power Series 50 Connector Assemblies 114- 13071

Rev B2 of 9 Tyco Electronics Corporation

2. REFERENCE MATERIAL

2.1. Revision Summary

SModified pneumatic tooling information in Figure 7

2.2. Customer Assistance

Reference Product Part Number 647845 and Product Code G802 are representative of Power Series 50

connector assemblies. Use of these numbers will identify the product line and expedite your inquiries through a

service network established to help you obtain product and tooling information. Such information can be

obtained through a local Representative or, after purchase, by calling PRODUCT INFORMATION at the

number at the bottom of page 1.

2.3. Drawings

Customer Drawings for product part numbers are available from the service network. If there is a conflict

between the information contained in the Customer Drawings and this specification or with any other technical

documentation supplied, call PRODUCT INFORMATION at the number at the bottom of page 1.

2.4. Instructional Material

Instruction Sheets (408--series) provide assembly instructions and Customer Manuals (409--series) provide

machine setup and operation procedures. Documents available which pertain to this product are:

408--4089 Ratcheted Cable Cutter Hand Tool 607453--2

408--4557 Heavy Duty Cable Cutter Hand Tool 605743--1

408--4559 Heavy Duty Cable Cutter Hand Tool 605744--1

408--4561 Heavy Duty Cable Cutter Hand Tool 600769--1

408--8059 General Preventive Maintenance for Miniature Quick--Change Applicators

408--8540 Crimp Tool 1526955--1

408--8636 Power Series 50 Connector Assemblies

408--9688 Cable Stripper/Slitter Tool 606700--1

408--9816 Handling of Reeled Products

409--1993 AMP--TAPETRONIC* Machine 69875

3. REQUIREMENTS

IMPORTANT: Using the exact products and application requirements described in this document will ensure

proper application; however, to ensure reliability of performance, it is highly recommended that an independent

evaluation be conducted of the chosen product combinations (wire, connector assemblies, and system) before

final application is approved.

3.1. Special Assembly Considerations and Safety

These connectors MUST NOT be used for interrupting current; otherwise, there is risk of electrical shock. In

any case, the electrical power supply must ALWAYS BE DISCONNECTED, and the connectors must ALWAYS

BE DE--ENERGIZED (this might include disconnecting the cable from the battery) before mating and unmating

or servicing the connectors.

It is highly recommended that these connectors not be used in external power applications where the electrical

potential exceeds 42 V. In applications where these connectors are located internal to a device and do not

serve as the primary means of connection, high voltages are allowable. It must be determined by the original

equipment manufacturer (OEM) whether the connectors meet electrical and safety requirements when used in

a specific application.

In applications where the connectors are used external to a device or as the primary means of disconnecting power

supplies or charging equipment, care must be taken to avoid touching exposed electrical contacts as there is risk of

electric shock.

DANGER

Power Series 50 Connector Assemblies 114- 13071

Rev B 3 of 9Tyco Electronics Corporation

3.2. Limitations

This product is designed to operate in a temperature range of --20_to 105_C[--4_to 221_F].

3.3. Material

The housing is made of polycarbonate, rated 94 V--0 by Underwriters Laboratories Inc. (UL). The springs

(inside the housing) are made of stainless steel. The contacts and reducing bushing are made of copper plated

with silver.

3.4. Storage

A. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the housing

material.

B. Shelf Life

The housings and contacts should remain in the shipping containers until ready for use to prevent

deformation. The housings and contacts should be used on a first in, first out basis to avoid storage

contamination that could adversely affect performance.

C. Chemical Exposure

Do not store housings or contacts near any chemical listed below as they may cause discoloration of the

plated finish of the contacts or stress corrosion cracking in the housing or contact material.

Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds

Amines Carbonates Nitrites Sulfur Nitrites Tartrates

3.5. Wire Selection and Preparation

The contacts accept stranded (recommended a minimum of 19 strands) copper wire sizes 6 through 12 AWG

with a maximum insulation diameter of 11.18 mm [.440 in.]. Contact size 6 can accept smaller wire sizes to a

minimum of size 16 AWG with the use of the appropriate size reducing bushing (as described in

Paragraph 3.6).

Wires with less than 19 strands may be too stiff and difficult to work with.

Tarnished copper wire must be thoroughly cleaned using a stiff wire brush, or other suitable method, that

penetrates the entire bundle and cleans every conductor. The wire must be restored to a bright copper finish.

The contact wire barrels are lined with silver plating to assure consistently high conductivity which will be

reduced if tarnished wire is used.

The wire must be cut to length. Proper strip length is necessary to properly insert the conductors into the

contact. The strip length of the wire is shown in Figure 2.

Reasonable care must be taken not to nick or scrape any part of the wire during the stripping.

12.06--13.33 [.475--.525]

Wire Strip Length

Note: Not to Scale

Figure 2

NOTE

CAUTION

Power Series 50 Connector Assemblies 114- 13071

Rev B4 of 9 Tyco Electronics Corporation

3.6. Reducing Bushing

Reducing bushings are available for contact size 6 to accommodate smaller wire sizes to a minimum of size

16 AWG. When required, the appropriate size reducing bushing must be installed onto the wire before inserting

the wire into the contact (the reducing bushing can be installed onto the wire before or after stripping the wire).

Placement of the reducing bushing must meet the requirements shown in Figure 3.

Figure 3

Ends of Conductors

Must Be Visible

1.52 [.060] Max

Reducing Bushing to Wire Insulation

Placement of Reducing Bushing on Stripped Wire

Placement of Wire and Reducing Bushing in Contact

0.38 [.015] Max

Reducing Bushing Protrudes from Contact

Wire and Reducing Bushing

Must Be Straight in Relation

to Contact Wire Barrel

Contact Size 6

Wire Insulation Must Not Enter Reducing Bushing

3.7. Crimp Requirements

A. Reducing Bushing

If a reducing bushing is used, the reducing bushing must be held firmly inside the contact wire barrel. The

reducing bushing must be straight in relation to the wire barrel and can protrude from the wire barrel to the

dimension provided in Figure 4.

B. Tab

The contact tab must not be deformed in any way. See Figure 4.

C. Wire Barrel Crimp

All conductors must be held firmly inside the wire barrel. The crimp applied to the contact wire barrel is the

most compressed area and most critical in ensuring optimum performance of the crimped contact. The

crimped area must be symmetrical on both sides of the wire barrel as shown in Figure 4.

The developed crimp configurations result from using the specific tooling described in Section 5, TOOLING.

D. Wire Conductor and Insulation Location

No conductors can be folded back over the wire insulation. The insulation must not enter the wire barrel.

The conductors must be visible between the reducing bushing, if applicable, or contact wire barrel and the

wire insulation within the dimension stated in Figure 4.

NOTE

Power Series 50 Connector Assemblies 114- 13071

Rev B 5 of 9Tyco Electronics Corporation

Detail A-A

Wire Insulation Does Not

Enter Contact Wire Barrel

No Loose Conductors or Conductors

Folded Over Wire Insulation

1.59 [.062] Max

Conductor Visible

Crimp Requirements

0.38 [.015] Max

Reducing Bushing (If Applicable)

Protrudes from Wire Barrel

Crimped Area Symmetrical on

Both Sides of Wire Barrel

Tab Not Deformed

in Any Way

Dual--Indent CrimpSingle--Indent Crimp

Figure 4

Note: Dual--indent crimp shown. Requirements apply equally to single--indent crimp.

Most Compressed Area

of Wire Barrel

Most Compressed Area

of Wire Barrel

E. Twist and Roll

There should be no twist or roll of the wire barrel of the crimped contact that would cause overstress or

impair usage. See Figure 5.

Figure 5

Uncrimped Portion

Crimped Portion

Avoid Twist

and Roll

Datum Line

Power Series 50 Connector Assemblies 114- 13071

Rev B6 of 9 Tyco Electronics Corporation

F. Bend Allowance

The force applied during crimping may cause some bending between the wire barrel and wire. Such

deformation is acceptable within the following limits.

1. Up and Down

The crimped portion must not be bent beyond the limits shown in Figure 6.

2. Side--to--Side

The crimped portion must not be bent from one side to the other beyond the limits shown in Figure 6.

Figure 6

Up and Down Alignment

Side-to-Side Alignment

Datum Line

Note: Dual--indent crimp shown. Requirements apply equally to single--indent crimp.

3.8. Keying

Assurance of proper mating is provided by a molded--in mechanical key at the mating face of the housing. The

position of the key of the mating housings must be compatible. The customer drawing for the specific housing

provides the key position.

Other key positions are available upon request.

3.9. Installing Contacts into Housing

The electrical supply MUST BE DISCONNECTED and the connectors MUST BE DE--ENERGIZED (this might include

disconnecting the cable from the battery) before installing the contacts into the housing.

The contacts must NOT be forced into the housing. Each contact must be installed in the housing according to

the following requirements.

1. Each contact must be inserted into the wire side of the housing.

2. The bottom of each contact must face the retention spring of the housing.

3. Each contact must be in straight alignment with the contact cavity.

4. Each contact must be fully latched onto the housing retaining spring.

NOTE

DANGER

Power Series 50 Connector Assemblies 114- 13071

Rev B 7 of 9Tyco Electronics Corporation

3.10. Removing Contacts from Housing

The housing retention spring must be depressed away from the underside of the contact to remove the contact

from the housing. A contact must be removed from the housing according to the following:

The electrical supply MUST BE DISCONNECTED and the connectors MUST BE DE--ENERGIZED (this might include

disconnecting the cable from the battery) before removing the contacts from the housing.

Section 5 lists available extraction tools used to remove these contacts.

1. The tip of the tool must be inserted between the sides of contact and the contact cavity at the mating

face of the housing.

2. The handle of the tool must be pushed down so that the housing retention spring is depressed away

from the underside of the contact. While holding the tool in position, the wire must be pushed down and

gently pulled back until the contact is free from the housing.

3.11. Mating and Unmating Connectors

The electrical supply MUST BE DISCONNECTED and the connectors MUST BE DE--ENERGIZED (this might include

disconnecting the cable from the battery) before mating or unmating the connectors.

The connectors must NOT be forced to mate or unmate. When fully mated, the housings must appear flush at

the point of engagement.

3.12. Repair

The contact, housing, and reducing busing are not repairable. Damaged or defective contacts, housings, or

reducing bushings must not be used. The contacts or reducing bushings must not be re--used by removing the

wire.

4. QUALIFICATION

Power Series 50 connector assemblies are Component Recognized by Underwriters Laboratories Inc. (UL) in

File E28476 and have been Investigated to CSA International Standards by UL.

5. TOOLING

Tooling part numbers and instructional material packaged with the tooling are shown in Figure 7.

5.1. Cable Cutters

These cable cutters are available for cutting the cable to length.

5.2. Hand Tools

Hand tools for manual application of loose piece contacts are available to cover the full wire size range.

Industry standard tooling for manual application of loose piece contacts is available for the full wire size range.

Recommended manufacturer and tooling description and part numbers are given in Figure 7.

Consult manufacturer’s literature for information on using the tooling.

5.3. Power Unit

A semi--automatic machine for power assisted application of tape and reeled contacts are available for the full

wire size range. The machine is designed to be used as stand--alone bench unit.

DANGER

NOTE

DANGER

NOTE

Power Series 50 Connector Assemblies 114- 13071

Rev B8 of 9 Tyco Electronics Corporation

5.4. Extraction Tool

The extraction tool or a standard insulated screwdriver with 1/4--in. flat blade must be used to remove contacts

from the housing.

5.5. Stripping Tool

The cable stripper is used to strip insulation from the cable.

Standard Insulated Screwdriver

With 1/4--in. Flat Blade

AMP--TAPETRONIC Machine

69875 (409--1993)

Extraction Tool 68265--1

(No Document)

Crimp Tool 1526955--1

(408--8540)

Heavy Duty Cable Cutter Hand Tool

600769--1 (408--4561)

Heavy Duty Cable Cutter Hand Tool

605743--1 (408--4557)

Heavy Duty Cable Cutter Hand Tool

605744--1 (408--4559)

Ratcheted Cable Cutter Hand Tool

607453--2 (408--4089)

Cable Stripper/Slitter Tool

606700--1 (408--9688)

Commercially Available Pneumatic Hand Crimping Tool,

Die Set, and Locator (Dual--Indent Crimp)

Available from Pacific Industrial Components (PICO)

Camarillo, CA (805) 388--5510

(http://www.picotools.com)

(See Table)

SERIES DIE SET LOCATOR

DIE CLOSURE FOR

CONTACT SIZE

6and8 10--12

414DA--4583

400 414DA--4582 4582--1

514DA--7033

.152 in. .134 in.

500 514DA--7034 7033--1

Figure 7

Power Series 50 Connector Assemblies 114- 13071

Rev B 9 of 9Tyco Electronics Corporation

6. VISUAL AID

Figure 8 shows a typical application of Power Series 50 connector assemblies. This illustration should be used

by production personnel to ensure a correctly applied product. Applications which DO NOT appear correct

should be inspected using the information in the preceding pages of this specification and in the instructional

material shipped with the product or tooling.

FIGURE 8. VISUAL AID

WIRE INSULATION MUST

NOT ENTER CONTACT

WIRE BARREL

CONTACTS MUST BE

SECURE IN HOUSINGS

THERE MUST BE

NO DAMAGE TO

CONNECTORS

CONTACT MUST BE

STRAIGHT AND NOT

DAMAGED IN ANY WAY

WIRE INSULATION MUST

NOT BE CUT OR BROKEN

REDUCING BUSHING (IF

APPLICABLE) MUST BE FLUSH

WITH, OR PROTRUDE SLIGHTLY

FROM, CONTACT WIRE BARREL

CONNECTORS MUST BE

FULLY MATED (HOUSINGS

APPEAR FLUSH AT POINT

OF ENGAGEMENT)

CONDUCTORS MUST BE VISIBLE BETWEEN

REDUCING BUSHING (IF APPLICABLE) OR

CONTACT WIRE BARREL AND WIRE INSULATION

THEREMUSTBENOLOOSE

CONDUCTORS OR CONDUCTORS

FOLDED OVER WIRE INSULATION

CRIMPED AREA MUST BE

SYMMETRICAL ON BOTH

SIDES OF WIRE BARREL

DUAL- INDENT CRIMP

SINGLE- INDENT CRIMP