1604037-1 - Tyco Electronics

Figure 1

Housing Closed-Barrel Contact

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.

Accessory

Reducing Bushing

(For Closed-Barrel Contact Size 1/0

Using Small Wire Size)

Application Specification

Power Series 175 (Double-Pole) 114-13118

LOC B

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2009 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 Assembly

15 JAN 09 Rev A

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 175 (double–pole) connector

assembly 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 1/0, 1, 2, and 4 and accept wire sizes (AWG) that correspond to

the contact size. Reducing bushings are available for contact size 1/0 to accommodate small wire sizes to a

minimum of size 10 AWG.

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 voltage.

The 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.

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

18 Orange

24 Red

36 Gray

48 Blue

80 Black

NOTE

Power Series 175 (Double-Pole) Connector Assembly 114-13118

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2. REFERENCE MATERIAL

2.1. Revision Summary

Initial release of application specification

2.2. Customer Assistance

Reference Product Base Part Number 1604037 and Product Code H416 are representative of Power Series

175 (double–pole) connector assembly. 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 tool setup and operating 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 605742–1

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

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

408–8868 Power Series 175 and 350 (Double–Pole) Connector Assemblies with Cable Clamp Kits

408–9688 Cable Stripper/Slitter Tool 606700–1

408–9816 Handling Reeled Products

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 wire 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.

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 Underwriter Laboratories, Inc. (UL) 94 V–0. The springs (inside

the housing) are made of stainless steel. The cable clamp is made of aluminum. The contacts and reducing

bushing are made of copper plated with silver.

DANGER

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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 1/0, 1, 2, and

4 AWG with a maximum insulation diameter of 19.05 [.750]. Contact size 1/0 can accept small wire sizes to a

minimum of size 10 AWG with the use of the appropriate 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.

26.4-27.6

[1.04-1.089]

Recommended Wire Strip Length

Note:

Not to Scale

Figure 2

3.6. Reducing Bushing

Reducing bushings are available for contact size 1/0 to accommodate small wires to a minimum of

size 10 AWG. When required, the appropriate size reducing bushing must be installed onto the wire

after

stripping the wire and

before

inserting the wire into the contact. Placement of the reducing bushing must meet

the requirements shown in Figure 3.

NOTE

CAUTION

Power Series 175 (Double-Pole) Connector Assembly 114-13118

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Figure 3

Ends of Conductors Visible

1.52 [.060] Max

Reducing Bushing to Wire Insulation

Placement of Reducing Bushing on Stripped Wire

Placement of Reducing Bushing and Wire in Contact

Wire and Reducing Bushing

Straight in Relation to

Contact Wire Barrel

Contact Size 1/0

Wire Insulation Does Not Enter Reducing Bushing

0.38 [.015] Max

Reducing Bushing to Contact Wire Barrel

3.7. Crimp Requirements

A. Reducing Bushing

If 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 must be flush with the end of the wire barrel or protrude

no more than the dimension provided in Figure 4.

B. Tab

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

C. Wire Barrel Crimp

All wire conductors 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. See Figure 4.

The developed dual-indent crimp configuration results from using the specific tooling described in Section 5,

TOOLING.

D. Wire Conductor and Insulation Location

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

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

the wire insulation within the dimension given in Figure 4.

The end of the wire must be flush with the end of the wire barrel or extend no more than the dimension

given in Figure 4.

E. Flash

There shall be no flash or extruded contact insulation visible in the crimped area. See Figure 4.

NOTE

Power Series 175 (Double-Pole) Connector Assembly 114-13118

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ÏÏÏÏ

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

Crimped Area Symmetrical on

Both Sides of Wire Barrel

Tab Not Deformed

in Any Way

Figure 4

Section A-A

ÌÌÌ

Most Compressed Area

of Wire Barrel

0.38 [.015] Max

Reducing Bushing (If Used) to Contact Wire Barrel

No Flash

F. 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

ÏÏ

G. 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.

Power Series 175 (Double-Pole) Connector Assembly 114-13118

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Figure 6

Up and Down Bend

Side-to-Side Bend

Datum Line

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 wire 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.

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 wire 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.

NOTE

DANGER

NOTE

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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 wire 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 175 (double–pole) connector assembly is Component Recognized by UL under File E28476 and

have been Investigated to CSA International Standards by UL.

The connector assembly meets the requirements of CSA International Standards by UL only when the cable clamps

indicated in this document are used.

5. TOOLING

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

5.1. Cable Cutter

The cable cutter is used to cut the wire to length.

5.2. Stripping Tool

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

5.3. Hand Crimping Tool

Industry standard tooling for pneumatic application of loose piece contacts is available for the full wire size

range. Recommended manufacturer and contact information is Pico Corporation, Camarillo, CA (805)

388–5510 (http://www.picotools.com).

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

5.4. Extraction Tool

The extraction tool is designed to remove contacts from the housing by releasing the contact locking lance

without overstressing the contact. A standard insulated screwdriver with a 1/4–in. blade can also be used to

remove the contacts from the housing.

DANGER

NOTE

Power Series 175 (Double-Pole) Connector Assembly 114-13118

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Extraction Tool 68265-1

(No Document)

Heavy Duty Cable Cutter Hand Tool

600769-1 (408-4561)

Heavy Duty Cable Cutter Hand Tool

605742-1 (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)

Pneumatic Power Crimping Tool with Locator and Die

(Commercially Available from Pico Corporation)

(See Table)

Standard Insulated Screwdriver

With 1/4-in. Flat Blade

CRIMPING TOOL

MODEL SERIES DIE DIE CLOSURE

DIMENSION

LOCATOR

500 DEC 514DA-10023 5.72 [.225] 10034-1

Figure 7

Die closure dimension is not crimp height dimension. If the die is dimensionally correct, the crimp height will be correct.

Power Series 175 (Double-Pole) Connector Assembly 114-13118

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6. VISUAL AID

The illustration below shows a typical application of Power Series 175 (double–pole) connector assembly. 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

THERE MUST BE NO LOOSE

CONDUCTORS OR CONDUCTORS

FOLDED OVER WIRE INSULATION

CRIMPED AREA MUST BE

SYMMETRICAL ON BOTH

SIDES OF WIRE BARREL

THERE MUST

BE NO FLASH