Instruction Sheet Power Series 50 Connector Assembly Kits 647891- [ ], 647892- [ ], and 647893- [ ] Closed Barrel Contact Reducing Bushing (Available Separately for Contact Size 6) Housing Contact Cavities Marking for Positive Polarity Marking for Negative Polarity Key (Position Varies) Each kit consists of a hermaphroditic housing and two closed barrel contacts. The contacts accept stranded (minimum of 19 strands recommended) copper wire with a maximum insulation diameter of 11.18 [.44]. Wire size (AWG) corresponds to the contact size. A reducing bushing is available for contact size 6 to accommodate smaller wire sizes to a minimum of size 16 AWG. See Figure 1. 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 housing is 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). i REDUCING BUSHING CONTACT Reduces to SIZE Part Number Wire Size (AWG) 647891--[ ] 8 647892--[[ ] 647893--[ ] 6 10--12 -- -- 647840--1 12--10 1445762--1 8 1445763--1 16--14 -- -- Figure 1 1. INTRODUCTION These instructions cover assembly and disassembly of Power Series 50 Connector Assembly Kits 647891--[ ], 647892--[ ], and 647893--[ ]. NOTE i NOTE i For detailed application requirements, refer to Application Specification 114--13071. Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale. 02 FEB 10 Rev A 2. DESCRIPTION NOTE CONNECTOR ASSEMBLY KIT 408-- 8636 Refer to the specific customer drawing for available colors. 3. ASSEMBLY PROCEDURE These Kits Must Be Assembled by A Qualified Electrician in Accordance with National and Local Electrical Codes and the Following Instructions. DANGER To avoid risk of electric shock 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 contacts. 1. Cut the wire to length. 2. Using Cable Stripper/Slitter Tool 606700--1, strip the wire to the dimension given in Figure 2. Be careful not to nick or scrape any part of the wire. 3. Thoroughly clean tarnished copper wire using a stiff wire brush, or other suitable method, that penetrates the entire bundle and cleans every conductor. Restore the wire to a bright copper finish. 12.06-- 13.33 [.475-- .525] Recommended Strip Length Note: Not to Scale Reasons for reissue of this instruction sheet are provided in Section 7, REVISION SUMMARY. 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. Insulation Conductors Figure 2 This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website at www.tycoelectronics.com 1 of 3 LOC B 408- 8636 Power Series 50 Connector Assembly Kits 647891- [ ], 647892- [ ], and 647893- [ ] NOTE i The contact wire barrel is lined with silver plating to assure consistently high conductivity which will be reduced if tarnished wire is used. 4. If used, slide the reducing bushing onto the wire conductors to the dimension given in Figure 3. Make sure that the wire insulation DOES NOT enter the reducing bushing and the ends of the conductors are visible. 7. Inspect the crimp according to the following: 1 2 3 4 1.52 [.060] Max Reducing Bushing (If Used) 5 6 Note: Not to Scale Wire Insulation Figure 3 7 5. Insert the wire conductors into the contact wire barrel until it stops. If used, the reducing bushing must be flush with the contact wire barrel or can protrude from the wire barrel no more than the dimension given in Figure 4. DO NOT allow the insulation to enter the wire barrel. wire insulation is not cut or broken reducing bushing (if used) is flush with, or protrudes slightly from, wire barrel wire insulation does not enter wire barrel contact is straight and not damaged in any way there are no loose conductors or conductors folded over wire insulation conductors are visible between reducing bushing (if used) or wire barrel and wire insulation crimped area is symmetrical on both sides of wire barrel Note: Dual-- Indent Crimp Shown Same Criteria Applies to Single-- Indent Crimp 1 0.38 [.015] Max Reducing Bushing (If Used) 2 5 3 Contact Wire Barrel Note: Not to Scale 6 4 Figure 4 7 6. Using any of the hand tools given in Figure 5, crimp the contact according to the instructions packaged with the tooling. TYCO ELECTRONICS (Single-- Indent Crimp) CRIMP TOOL 1526955-- 1 (408 - 8540) (408- PICO CORPORATIONH PNEUMATIC HAND TOOL (Dual-- Indent Crimp) AMERICAN ELECTRICAL TERMINAL (AET) HAND TOOL T-- 406 SERIES 400 Adapter 1527508--1 (Marking A) Adapter 5992 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 H Tooling available from Pacific Industrial Components (PICO) Corporation at http://www.picotools.com Figure 5 2 of 3 Tyco Electronics Corporation Rev A 408- 8636 Power Series 50 Connector Assembly Kits 647891- [ ], 647892- [ ], and 647893- [ ] 8. Refer to Figure 6, and install each contact into the housing as follows: DANGER To avoid risk of electric shock, DISCONNECT the electrical supply and DE--ENERGIZE the connectors (this might include disconnecting the cable from the battery) before installing the contacts into the housing. Point of Engagement a. From the wire side of the housing, align the contact with the appropriate contact cavity making sure that the underside of the contact faces the housing retention spring. b. Insert the contact straight into the contact cavity until an audible "click" is heard. Slightly pull back on the wire to make sure that the contact is fully latched onto the retention spring. CAUTION DO NOT force the contacts into the housing. ! Figure 7 5. DISASSEMBLY DANGER Wire Side of Housing Underside of Contact To avoid risk of electric shock, DISCONNECT the electrical supply and DE--ENERGIZE the connectors (this might include disconnecting the cable from the battery) before removing the contacts into the housing. 1. Pull the housings straight apart (DO NOT force them to unmate). 2. Using Extraction Tool 68265--1 (or a standard insulated screwdriver with 1/4--in. flat blade), remove each contact from the housing as follows: a. At the mating face of the housing, insert the tip of the tool between either side of the contact and the contact cavity. b. Push the handle of the tool toward the bottom (flat side) of the housing so that the housing retention spring is depressed away from the underside of the contact. While holding the tool in position, push the wire in the same direction, and gently pull back until the contact is free from the housing. Retention Spring Figure 6 6. REPLACEMENT AND REPAIR 4. MATING (Figure 7) DANGER To avoid risk of electric shock, DISCONNECT the electrical supply and DE--ENERGIZE the connectors (this might include disconnecting the cable from the battery) before mating or unmating the connectors. Align the mating faces of the housings, and push the housings together. DO NOT force the housings to mate. When fully mated, the housings must appear flush at the point of engagement. Rev A The contact, housing, and reducing busing are not repairable. DO NOT use damaged or defective contacts, housings, or reducing bushings. DO NOT re--use terminated contacts or reducing bushings by removing the wire. 7. REVISION SUMMARY Revisions to this instruction sheet include: S Updated instruction sheet to corporate requirements S Changed die set part numbers for pneumatic tool in Figure 5 Tyco Electronics Corporation 3 of 3