1604084-1 - Tyco Electronics

Application Specification

Power Series 15, 30, and 45 114-13127

LOC B

of 22

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

(Single-Pole) Connector Assemblies

15 JAN 09 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 15, 30, and 45 (single–pole)

connector assemblies used in high–current systems for office furniture, power supplies, battery chargers,

telecommunications, and material handling equipment. Each connector assembly consists of a housing and an

open–barrel barrel (cold–headed) or closed–barrel (stamped–and–formed) contact. Accessories available for

the connector assemblies are a cable clamp kit, spiral retainer pin, spacer (short and long), mounting wing,

mounting clamp, plug frame (with latches and without latches), and panel mount frame.

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.

Figure 1

Housing Contacts

Dovetail

(4 Places)

Contact

Cavity

Accessories

Blade

Wire Barrel

Stabilizer

Tab

Mounting Wing

Dovetail

(2 Places)

Half Round

(2 Places)

Mounting

Hole

Retaining

Spring (Inside)

Mounting Clamp

(For 3 Stacked Housings

Shown)

Blade

Wire Barrel

Short Spacer

Open-Barrel Closed-Barrel

Wire

Stop

Long SpacerSpiral

Retainer Pin

Latch

(2 Places)

Cable Clamp Kit

Plug Frame

With Latches

Plug Frame

Without Latches

Screw

(2 Included)

Cable

Clamp

Panel Mount Frame

Mounting

Flange

Spiral Retainer

Pin Hole

Mounting

Hole

Cable End

Contact Stop

(Inside)

Cable

End Cable End

Mounting Latch

(2 Places)

Mating Face

Hood

Tongue

Latching Tab

(2 Places)

Spiral Retainer

Pin Holes

NOTE

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

of 22 Tyco Electronics Corporation

These connectors are designed for free–hanging, surface mount, and panel mount applications.

1.1. Features

The housing features a contact cavity, dovetails, and half rounds. The contact cavity has an internal retaining

spring that retains the contact in the housing. The housings can be joined with other housings on all four sides

using the dovetails. The hermaphroditic design of the housing ensures proper polarity in mating. The housings

are color coded to provide visual reference for proper mating of the connectors.

The open–barrel contact features a wire barrel, blade, and stabilizer tab. When the contact is inserted into the

housing, the stabilizer tab ensures proper insertion depth for the blade to engage the internal retaining spring.

These contacts are available in reeled form for terminating with a semi–automatic machine and loose piece

form for terminating with a manual hand tool.

The closed–barrel contact features a wire barrel, blade, and wire stop. When the contact is inserted into the

housing, the wire stop ensures proper insertion depth for the blade to engage the internal retaining spring.

These contacts are available in loose–piece form for terminating with a manual hand tool.

1.2. Accessories

A. Cable Clamp Kit

The cable clamp kit consists of a cable clamp and two screws. The kit is designed to be installed onto the

the plug frame to provide strain relief for the cable. The kit is available for 4–, 6–, and 8–pole (number of

stacked housings) plug frames.

B. Spiral Retainer Pin

The spiral retainer pin is used to hold stacked housings together or retain the stacked housings in the

frame. The spiral retainer pin is available in three lengths: 6.35 [.25] (short; for use in a single row of

housings), 11.18 [.44] (medium; for use in a double row of housings), and 21.6 [.85] (long; for use in a

frame).

C. Spacer

The spacer is available in short and long. The short spacer is used to fill voids in an uneven amount of

stacked housings, and the long spacer is used in conjunction with the short spacer to create polarized

keying. The spacers are color coded to provide visual reference for matching corresponding spacers.

D. Mounting Wing

The mounting wing is used to mount housings onto a surface. The mounting wing features dovetails that

are used to interlock the housings and adjacent mounting wings. The mounting wing must be secured to

the surface using commercially available hardware.

E. Mounting Clamp

The mounting clamp is used to mount housings onto a panel. The mounting clamp is secured to the panel

using commercially available hardware.

F. Frames

The frames—plug with latches, plug without latches, and panel mount—accommodate 2 to 8 housings (a

double row with a maximum of 4 housings). The frames are used for orderly cable management. The

integral latches and latching tabs prevent accidental disconnection of mated connectors. The plug frame

with latches mates with the plug without latches for free–hanging applications or with the panel mount

frame for panel mount applications.

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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Tyco Electronics Corporation

2. REFERENCE MATERIAL

2.1. Revision Summary

Revisions to this application specification include:

Updated document to corporate requirements

Changed product code in Paragraph 2.2

Changed nomenclature for contacts

Added text to Paragraph 3.9

Added document reference for extraction tool and changed part number for Model “K” terminating

machine in Figure 20

2.2. Customer Assistance

Reference Product Part Number 1604116 and Product Code H300 are representative of Power Series 15, 30,

and 45 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 product assembly instructions or tooling setup and operation

procedures and Customer Manuals (409–series) provide machine setup and operation procedures. Documents

available which pertain to this product are:

408–8040 Heavy Duty Miniature Quick–Change Side Feed Applicator

409–5128 AMP–O–LECTRIC* Model “K” Terminating Machine

409–5842 AMP–O–LECTRIC Model “G” Terminating Machine 354500–1

3. REQUIREMENTS

3.1. Material

The housing, mounting wing, and spacer are made of polycarbonate, rated 94 V–0 by Underwriter

Laboratories, Inc. (UL). The contacts are made of copper plated with silver or tin. The spiral retainer pin is

made of stainless steel.

3.2. 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

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

of 22 Tyco Electronics Corporation

3.3. Cable Selection and Preparation

The contacts accept stranded copper cable sizes 20 through 10 AWG with a minimum of 19 wire strands and a

maximum insulation diameter of 18.16 [.175].

Cable with less than 19 wire strands must not be used. Cable with less than 19 wire strands is too stiff and could

cause the contact to twist inside the housing when dressing the cable.

The cable must be cut to length. Proper strip length is necessary to properly insert the wires into the contact.

The strip length of the cable is shown in Figure 2.

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

Strip Length (Refer to Table)

Recommended Cable Strip Length

Note:

Not to Scale

CONNECTOR

CABLE SIZE

CABLE STRIP LENGTH

CONNECTOR

SERIES

CABLE SIZE

RANGE (AWG) Open-Barrel

Contact Closed-Barrel

Contact

20-16 4.30-6.48

[.170-.255] Ċ

18-16 Ċ 7.87-8.89

[.309-.350]

16-12 4.30-6.48

[.170-.255] Ċ

14-12 Ċ 7.87-8.89

[.309-.350]

45 14-10 5.71-6.98

[.225-.275] Ċ

Figure 2

3.4. Crimp Requirements

The following crimp requirements result from using the tooling described in Section 5.

A. Open-Barrel Contact Using Semi-Automatic Machine

The crimped open–barrel contact using the semi–automatic machines must meet the requirements given

in Figure 3.

The cutoff tab is the remaining portion of the carrier strip after the contact is cut from the strip. The cutoff

tab and the burr resulting from the cutoff tab shearing must not exceed the dimension given in Figure 3

(Detail).

All cable wires 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. The crimp height and width must be within the

dimensions provided in Figure 3.

NOTE

CAUTION

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B 5

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Tyco Electronics Corporation

0.75 [.03] Max

Rear Bellmouth Height

No Front Bellmouth 4.06 [.16] Max

Rear Bellmouth Width

0.26 [.010] Max Flash

(Extruded Cable Insulation)

Section X-X

Wire Barrel Crimp Height

(Not Including Flash)

(See Table)

Wire Barrel Crimp

Width (See Table)

2.47 [.097] Max

Wires Visible Between Wire Barrel and

Cable Insulation

0.2 [.008] Max Burr

0.4 [.016] Max

Cutoff Tab

Wire Barrel Seam Completely Closed

with No Evidence of Loose Wire Strands

or Wire Strands Visible in Seam

Cable Insulation Does Not Enter

Wire Barrel (Allowed to Butt

Against Wire Barrel)

Blade Not Deformed

in Any Way

Cutoff Tab (2 Places)

See Detail

Detail

Stabilizer Tab Not Deformed

in Any Way

Open-Barrel Contact Crimp Requirements

Using Semi-Automatic Machines

No Wires Folded Back

Over Wire Insulation

All Wires Held Firmly in Wire Barrel

Crimp is Symmetrical on

Both Sides of Wire Barrel

End of Wires Flush With or Extends No More

Than 2.54 [.100] from End of Wire Barrel

CONNECTOR

SERIES CABLE SIZE

(AWG) CRIMP HEIGHT

+0.08 [+.003] CRIMP WIDTH

+0.08 [+.003]

20 1.50 [.059]

15 18 1.63 [.064] 3.05 [.120]

16 1.75 [.069]

16 1.96 [.077]

30 14 2.13 [.084] 3.56 [.140]

12 2.39 [.094]

14 2.44 [.096]

45 12 2.67 [.105] 3.94 [.155]

10 2.95 [.116]

Figure 3

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

of 22 Tyco Electronics Corporation

B. Open-Barrel Contact Using Hand Tool

The crimped open–barrel contact using the hand tool must meet the requirements given in Figure 4.

The crimp applied to the wire barrel is the most compressed area and most critical in ensuring optimum

performance of the crimped contact. The crimp height and width must be within the dimensions provided

in Figure 4.

Open-Barrel Contact Crimp Requirements

Using Hand Tool

Crimp Height (See Table)

Measure Here

Wire Barrel Seam Completely Closed

with No Evidence of Loose Wire Strands

or Wire Strands Visible in Seam

All Wires Held Firmly in

Wire Barrel

Crimp is Symmetrical on

Both Sides of Wire Barrel

No Wires Folded Back

Over Cable Insulation

Blade Not Deformed

in Any Way Stabilizer Tab Not

Deformed in Any Way

2.47 [.097] Max

Wires Visible Between Wire Barrel and

Cable Insulation

End of Wires Flush with Wire Barrel or

Extends No More Than 2.47 [.097] from

End of Wire Barrel

Cable Insulation Does Not Enter

Wire Barrel (Allowed to Butt

Against Wire Barrel)

CONNECTOR

CABLE SIZE

CLOSED-BARREL CONTACT

CONNECTOR

SERIES

CABLE SIZE

(AWG) CRIMP HEIGHT

+0.08 [+.003] CRIMP WIDTH

+0.08 [+.003]

45 10 3.12 [.123] 4.47 [.176]

Figure 4

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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B 7

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Tyco Electronics Corporation

C. Closed-Barrel Contact Using Hand Tool

When placing the closed–barrel contact in the tool, it is important to make sure that the contact is not

positioned upside–down. The contact must be positioned in the tool with the seam of the wire barrel facing

squarely toward the upper die. See Figure 5.

The crimped closed–barrel contact using the hand tool must meet the requirements given in Figure 5.

The crimp applied to the wire barrel is the most compressed area and most critical in ensuring optimum

performance of the crimped contact. The crimp height and width must be within the dimensions provided

in Figure 5.

Closed-Barrel Contact Crimp

Requirements Using Hand Tool

Blade Not Deformed

in Any Way

Slight Deformation of

Wire Stop is Acceptable

Wire Barrel Seam Completely Closed

with No Evidence of Loose Wire Strands

or Wire Strands Visible in Seam

No Wires Folded Back

Over Cable Insulation

2.47 [.097] Max

Wires Visible Between Wire Barrel and

Cable Insulation

Cable Insulation Does Not Enter

Wire Barrel (Allowed to Butt

Against Wire Barrel)

End of Wires Butt

Against Wire Stop

All Wires Held Firmly in

Wire Barrel

Crimp is Symmetrical on

Both Sides of Wire Barrel

Crimp Height (See Table)

Measure Here

Proper Position of Closed-Barrel Contact in Hand Tool

Upper Die (For Clarity, Tool Not Shown)

Seam of Wire Barrel

CONNECTOR

CABLE SIZE

CLOSED-BARREL CONTACT

CONNECTOR

SERIES

CABLE SIZE

RANGE (AWG) CRIMP HEIGHT

+0.08 [+.003] CRIMP WIDTH

+0.08 [+.003]

15 14-12 1.83 [.072] 3.23 [.127]

30 18-16 1.96 [.077] 3.56 [.140]

Figure 5

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

of 22 Tyco Electronics Corporation

3.5. 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 6.

Figure 6

Closed-Barrel ContactOpen-Barrel Contact

Wire Barrel

Avoid Twist and Roll

Datum Line Datum Line

Stabilizer

Tab

End of Wires

Blade

(Reference Point)

Wire Barrel

Wire Stop

End of Wires

Blade

(Reference Point)

3.6. Bend Allowance

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

deformation is acceptable within the following limits.

1. Up and down — the contact must not be bent beyond the limits shown in Figure 7.

2. Side–to–side — the crimped portion of the contact must not be bent from one side to the other.

Figure 7

Up and Down Bend

Datum Line

Max

Open-Barrel Contact

Closed-Barrel Contact

Side-to-Side Bend

Datum Line

Up and Down Bend

Side-to-Side Bend

Datum Line

Max

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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B 9

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Tyco Electronics Corporation

3.7. Special Assembly Considerations

— For optimum results, it is recommended intermating housings containing contacts with the same plating

(tin to tin or silver to silver).

— DO NOT restrict movement of the contacts that would affect their performance (such as bending

unsupported cables).

— DO NOT restrict heat dissipation from the connectors.

3.8. Installing Contact into Housing

A contact must be inserted into the cable end of the housing with the bottom of the contact facing the retaining

spring of the housing. The contacts MUST NOT be forced into the housing. The installed contact must meet

the requirements given in Figure 8.

Figure 8

Requirements of Installed Contact

Closed-Barrel Contact Shown, Same Requirements Apply to Open-Barrel Contact

Contact Wire Stop is Against

Housing Contact Stop

Contact Blade is Fully Latched

onto Retaining Spring of Housing

Cable is Straight in

Relation to Housing

Installing Contact into Housing

Cable End of Housing

Bottom of Contact

(Cross-Section)

Retaining Spring

of Housing

Hood (Ref)

Stabilizer Tab is Against

Housing Contact Stop

Contact Blade is Fully Latched

onto Retaining Spring of Housing

Cable is Straight in

Relation to Housing

Open-Barrel Contact

Closed-Barrel Contact

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B10

of 22 Tyco Electronics Corporation

3.9. Stacking Housings and Installing Spiral Retainer Pins

The housings must be interlocked using the dovetails. A housing must be slid onto another housing from the

mating face of the housings until the dovetails are engaged, the ends of the housings are flush, and the half

rounds of the housings form a hole. Refer to Figure 9, Detail A.

The housings can be stacked in a vertical, horizontal, or block configuration. A spiral retainer pin—using a

short for horizontal and a medium for block—should be inserted into the formed hole to hold the stacked

housings together. When seated, the spiral retainer pin must be flush with the top and bottom of the stacked

housings. One spiral retainer pin should be installed into each formed hole. For 2 vertical stacked housings,

one retainer pin should be inserted into one of the formed half holes. See Figure 9, Detail B.

Commercially available roll pins MUST NOT be used. Roll pins could fall out of the housings and cause damage to the

system.

Stacked housings can be permanently bonded by applying a small drop of cyanoacrylate glue to the joint

between the dovetails.

Figure 9

Stacking Housings

Vertical Horizontal Block

Joint Between

Dovetails

Mating Face

of Housings

Spiral Retainer

Pin (Optional)

Formed Hole

Detail A Detail B

Standard direct current (DC) connectors recommended by the Radio Amateur Civil Emergency Service

(RACES) must be stacked as shown in Figure 10. Red (as positive) and black (as negative) are the

recommended housing colors.

Figure 10

Red (Positive)

Housing

Black (Negative)

Housing

Hood

Tongue

RACES Recommended Standard DC Connectors

CAUTION

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B11

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Tyco Electronics Corporation

3.10. Installing Spacer

When stacking an uneven amount of housings, a short spacer must be used to fill the void(s). If keying is

desired, a short spacer must be used in one stack and a long spacer must be used in the mating stack. The

spacers must be installed in corresponding positions of the mating housings. Refer to Figure 11.

The housings and spacers must be interlocked using the dovetails. The half rounds of the housings and

spacers must form a hole.

Figure 11

Short

Spacer

Mating 3 Stacked Connectors Shown

Spiral Retainer Pin

(Ref, Optional)

Installing Spacer

Long

Spacer

Spiral Retainer Pin

(Ref, Optional)

3.11. Installing Plug Frame, Panel Mount Frame, and Spiral Retainer Pins

Stacked housings to be installed into a frame must not contain any spiral retainer pins. The cable of the

stacked housings must be fed through the mating face of the frame until the housings are seated in the frame.

A long spiral retainer pin must be used to retain the stacked housings (and if used, spacers) in the frame.

Exploded view is shown in Figure 12.

The spiral retainer pin must be installed through a spiral retainer pin hole in the frame and into the formed hole

of the stacked housings (and if used, spacers). When seated, the spiral retainer pin must be flush with the top

and bottom of the frame. One spiral retainer pin should be installed for each formed hole of the stacked

housings.

Commercially available roll pins MUST NOT BE USED. Roll pins could fall out of the frame and cause damage to the

system.

Spiral retainer pins must be installed in compatible hole positions for the mating frames. To ensure

compatibility, there must be two empty holes between the spiral retainer pins of mated frames. Compatible hole

positions are given in Figure 12.

Spiral retainer pins installed in incompatible hole positions prevent the connectors from mating. This

arrangement could be used for keying purposes or to prevent the energized side of the connection from

accidental exposure to a shorting object.

3.12. Installing Cable Clamp Kit

The cable clamp must be installed over the cable and onto the plug frame so that the ends of the cable clamp

are flat against the frame. The cable must not be pinched. The screws must be secure. An exploded view is

shown in Figure 12.

To avoid damage to the frame, screws must not be over-tightened.

CAUTION

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B12

of 22 Tyco Electronics Corporation

Installing Plug Frame (Exploded View)

Plug Frame With Latches Shown, Same Requirements Apply to Plug Frame Without Latches

Installing Panel Mount Frame (Exploded View)

4 Stacked Connectors

(Ref)

Cable Clamp

Spiral Retainer Pin

4-Pole Plug Frame (Ref)

4-Pole Panel Mount Frame (Ref)

Screws

Mating Face

4 Stacked Connectors

(Ref)

Spiral Retainer Pin

Mating Face

Plug Frame With Latches Plug Frame Without Latches

Compatible Hole Positions of Spiral Retainer Pins for Mating Frames

is Hole,

is Spiral Retainer Pin

Panel Mount Frame

-Or-

Housing

Figure 12

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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B 13

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Tyco Electronics Corporation

3.13. Panel Cutout

The panel thickness range shall be 0.76 through 3.40 [.030 through .134]. The panel must be cut using the

dimensions provided in Figure 13.

Panel Cutout for Panel Mounting

3.96 [.156]

(2 Places)

8.64 [.34]

17.27 [.680]

8.41 [.331]

25.4 [1.000]

12.7 [.50]

Single Row Double Row

3.96 [.156]

(2 Places)

16.31 [.642]

Panel Cutout for Surface Mounting

23.21 [.914]

16.21 [.638]

Number of Housings and If Used, Spacers (



15.71 [.6185]) + 0.5 [.019]

8.92 [.351]

4.5 [.178]

Panel Mount Frame

25.4 [1.00]

Note:

Not to Scale

Through Surface Mount Vertical or Surface Mount

23.21 [.914]

4.5 [.178]

Mounting Clamps

Mounting Wings

TOTAL NUMBER OF HOUSINGS AND SPACERS DIMENSION

Single Row Double Row A B

2 4 16.31 [.642] 31.75 [1.25]

3 6 24.21 [.953] 41.15 [1.62]

4 8 32.11 [1.264] 47.75 [1.88]

Figure 13

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B14

of 22 Tyco Electronics Corporation

3.14. Surface Mounting

Two mounting wings—one on each side of a housing or stacked housings—and commercially–available

hardware (two No. 6 pan head screws and nuts) are required to mount housings onto the surface. The length

of the screws must be determined by measuring the thickness of the surface, mounting wing, and nut.

Mounting wings can be used with up to 8 stacked housings. Spacers must be used with an uneven amount of

stacked housings.

The mounting wings are designed to provide sufficient support for NO MORE than 8 stacked housings.

Each mounting wing must be installed onto the housing from the mating face of the housings so that the

dovetails engage, and the end of mounting wings are even with the housings. Refer to Figure 14.

Figure 14

Mating Face

of Housings

Installing Mounting Wings

Mounting Wing

Even with Housings

Dovetails Are Engaged

Mounting Wing

2 Stacked

Connectors (Ref)

The housings can be mounted onto the front or back of the surface with the housings through the surface, on

the surface, or vertical to the surface. To ensure proper mating, care must be used to avoid interference

between adjacent mounted housings and other components. When installed, the mounting wings must be fully

seated on the panel and the hardware secure. See Figure 15.

Figure 15

Through Surface Mount

Cable

Housing

Mounting Wing

(2 Places)

Surface Mount

Cable

Mounting Wing

(2 Places)

Vertical Surface Mount

8-32 Screw

(2 Places) Housing

Cable

Surface

Mounting Wing

(2 Places)

8-32 Nut

(2 Places)

8-32 Screw

(2 Places)

8-32 Nut

(2 Places)

8-32 Screw

(2 Places)

8-32 Nut

(2 Places)

Surface Mounting

3 Stacked Connectors Shown, Same Requirements Apply to All Others

Surface

Housing

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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Tyco Electronics Corporation

3.15. Panel Mounting

A. Using Mounting Clamp

Two mounting clamps—one on top and one on bottom of the stacked housings—and commercially–

available hardware (two No. 6 pan head screws and nuts) are required to mount housings onto the panel.

The length of the screws must be determined by measuring the thickness of the panel, mounting clamp,

and nut. The mounting clamps are designed to be used with housings not containing spiral retainer pins.

The mounting clamp is available for up to 8 stacked housings. When installed, the mounting clamp must

be flat against the panel and the hardware secure. Dimensions for clearance are given in Figure 16.

Panel Mounting Using Mounting Clamps

Single Row Double Row

27.94 [1.1]

35.56 [1.4]

Mounting Clamp

(2 Places)

Panel

Screw

(2 Places) Panel

Screw

(2 Places)

Mounting Clamp

(2 Places)

Note:

Not to Scale

6 Stacked

Connectors

(Ref)

3 Stacked

Connectors

(Ref)

NUMBER OF HOUSINGS AND, IF USED, SPACERS

DIMENSION A

Single Row Double Row

DIMENSION A

2 4 22.85 [.9]

3 6 33.02 [1.3]

4 8 40.64 [1.6]

Figure 16

B. Using Panel Mount Frame

The panel mount frame is designed to be be front panel mounted. The mounting flange of the panel mount

frame must be flat against the panel. See Figure 17.

Figure 17

Panel Mounting Using Panel Mount Frame

Front of Panel

Mating Face

Mounting Flange is Flat Against Panel

4 Stacked Connectors (Ref) Cable

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B16

of 22 Tyco Electronics Corporation

3.16. Mating

A. Housings

Housings must be slid together until there is no gap between the hood of the housing and the mated

housing. Refer to Figure 18.

Figure 18

Mating Housings

Free-Hanging Housings Shown, Same Requirements Apply to Surface-Mounted and Panel-Mounted Housings

There Is No Gap Between

Hood of Housing and

Mated Housing

B. Frames

The mating faces of the plug frames must be aligned, then pushed together until the latch engages the

latching tab. Refer to Figure 19.

Spiral retainer pins located in incompatible hole positions will prevent frames from latching.

Figure 19

Mating Frames

Plug Frame With Latches Mated to Plug Frame Without Latches Shown

Same Requirements Apply to Panel Mount Frame

(Top View)

Latch (Plug Frame With Latches)

Latching Tab (Plug Frame Without Latches)

3.17. Strain Relief

When bending or forming cable, the bundle must be held at least 6.35 [.250] beyond the back of the housing or

frame before bending in any direction. For mated housings, if the installation is to be subject to bending forces,

strain relief should be provided on the cable bundle approximately 25.4 [1.0] from the back of the housing.

NOTE

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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Tyco Electronics Corporation

Unsupported cable must not be bent as this may cause strain on the contacts inside the housing.

3.18. Disassembly

A. Unmating Housings and Extracting Contact

If used, the spiral retainer pin must be removed (the pin must be pushed through the formed hole of the

housings until exposed, then pulled out of the opposite side). The housings must be unmated by grasping

the housings and pulling them straight apart. DO NOT disconnect under load (not for interrupting current).

To avoid personal injury, electrical supply MUST BE DISCONNECTED BEFORE unmating housings.

Contacts must be extracted by inserting the tip of the tool into the front of the housing, depressing the

retaining spring toward the tongue of the housing, then grasping the cable, the contact can be pulled

straight out of the housing (refer to Section 5 for description of tooling).

B. Accessories

The frames must be unmated by depressing the latches of the plug frame, then pulling the frames straight

apart. The accessories must be disassembled in the following order:

Plug Frame — 1) remove cable clamp, 2) remove spiral retainer pin(s): each pin must be pushed through

the hole of frame until exposed, then pulled out of the opposite side, 3) remove housings: the cable must

be pushed until the housing stack is out of the frame.

Panel Mount Frame — 1) remove frame from panel: mounting latches must be depressed, then the frame

can be pushed through the panel, 2) remove spiral retainer pin(s): each pin must be pushed through the

hole of the frame until exposed, then pulled out of the opposite side, 3) remove housings: the cable must

be pushed until the housing stack is out of the frame.

3.19. Repair

Damaged or defective connectors, contacts, or accessories MUST NOT be used. Contacts MUST NOT be

re–used by removing the cable.

4. QUALIFICATION

Power Series 15, 30, or 45 connector assemblies are Component Recognized by Underwriter Laboratories,

Inc. (UL) under 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 given in Figure 20.

5.1. Extraction Tool

The extraction tool or a standard insulated screwdriver with a 1/8–in. or 2–mm flat blade must be used to

remove a contact from the housing.

5.2. Hand Tool

Commercially–available hand tools for manual application of loose–piece contacts are available. It is

recommended using the PWRcrimp powerpole crimp tool from West Mountain Radio

(http://www.westmountainradio.com). This hand tool should be used for field repair only.

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

CAUTION

NOTE

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B18

of 22 Tyco Electronics Corporation

5.3. Applicators

The applicators are designed to crimp reeled open–barrel contacts onto pre–stripped cable. Crimping dies are

included with the applicator.

5.4. Semi-Automatic Machines

The machines provide the force required to drive the applicator. These machines are designed to be bench

mounted and are operated by a foot pedal. These machines provide for high volume, heavy duty production

requirements.

CABLE SIZE RANGE

(AWG) CONNECTOR

SERIES CONTACT TYPE

14-12 15

Closed Barrel

18-16 30

Closed Barrel

10 45 Open Barrel

Heavy Duty Miniature Quick-Change

Side Feed Applicator (Refer to Table)

(408-8040)

AMP-O-LECTRIC Model G"

Terminating Machine 354500-1

(409-5842)

Strip Form Open-Barrel Contact

AMP-O-LECTRIC Model K"

Terminating Machine

2-565435-2 (409-5128)

CABLE SIZE RANGE (AWG) CONNECTOR SERIES APPLICATOR

20-16 15 1385450-3

16-12 30 1385468-3

14-10 45 1385469-3

Figure 20

PWRcrimp Powerpole Crimp Tool

(Available from West Mountain Radio)

Loose-Piece Open-Barrel and Closed-Barrel Contacts

Extraction Tool 68265-1

(Refer to 408-2597)

or Standard

Insulated Screwdriver

With 1/8-in. or 2-mm Flat Blade

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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Tyco Electronics Corporation

6. VISUAL AID

The illustration below shows a typical application of Power Series 15, 30, and 45 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 21. VISUAL AID (CONT’D)

CRIMPED CONTACT

BLADE MUST NOT

BE DEFORMED IN

ANY WAY

WIRE STOP CAN BE

SLIGHTLY DEFORMED

WIRE BARREL SEAM MUST BE

COMPLETELY CLOSED WITH NO

EVIDENCE OF LOOSE WIRE STRANDS

OR WIRE STRANDS VISIBLE IN SEAM

THERE MUST BE NO WIRES FOLDED BACK

OVER CABLE INSULATION

WIRES MUST BE VISIBLE BETWEEN WIRE

BARREL AND CABLE INSULATION

CABLE INSULATION MUST NOT ENTER

WIRE BARREL, HOWEVER MAY BUTT

AGAINST WIRE BARREL

END OF WIRES MUST BUTT

AGAINST WIRE STOP

ALL WIRES MUST BE HELD

FIRMLY IN WIRE BARREL

CRIMP MUST BE

SYMMETRICAL ON BOTH

SIDES OF WIRE BARREL

CLOSED-BARREL CONTACT

OPEN-BARREL CONTACT

(Using Semi-Automatic Machine)

FOR STRIP FORM CONTACTS,

CUTOFF TAB AND BURR MUST NOT

EXCEED REQUIRED DIMENSIONS

BLADE MUST NOT

BE DEFORMED IN

ANY WAY

WIRE BARREL SEAM MUST BE COMPLETELY CLOSED

WITH NO EVIDENCE OF LOOSE WIRE STRANDS OR

WIRE STRANDS VISIBLE IN SEAM

CRIMP MUST BE

SYMMETRICAL ON BOTH

SIDES OF WIRE BARREL

WIRES MUST BE VISIBLE BETWEEN WIRE

BARREL AND CABLE INSULATION

REAR BELLMOUTH

MUST BE VISIBLE

STABILIZER TAB MUST

BE NOT DEFORMED IN

ANY WAY

FOR STRIP FORM CONTACTS,

CUTOFF TAB AND BURR MUST NOT

EXCEED REQUIRED DIMENSIONS CABLE INSULATION MUST NOT ENTER

WIRE BARREL, HOWEVER MAY BUTT

AGAINST WIRE BARREL

END OF WIRES MUST BE FLUSH

WITH OR EXTEND SLIGHTLY

BEYOND WIRE BARREL

THERE MUST BE NO WIRES

FOLDED BACK OVER CABLE

INSULATION

ALL WIRES MUST BE HELD

FIRMLY IN WIRE BARREL

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B20

of 22 Tyco Electronics Corporation

FIGURE 21. VISUAL AID (CONT’D)

PLUG FRAME WITH LATCHES MATED TO

PLUG FRAME WITHOUT LATCHES

FREE-HANGING APPLICATION

HOUSINGS MUST NOT BE

DAMAGED IN ANY WAY

EACH CONTACT BLADE MUST

BE FULLY LATCHED ONTO

RETAINING SPRING OF HOUSING

CABLE MUST BE STRAIGHT

IN RELATION TO HOUSING

FOR STACKED HOUSINGS,

IF USED, SPIRAL RETAINER PIN

MUST BE FLUSH WITH TOP

AND BOTTOM OF HOUSINGS

FOR STACKED HOUSINGS, EACH

FORMED HOLE SHOULD CONTAIN

A SPIRAL RETAINER PIN

THERE MUST BE NO GAP

BETWEEN HOOD OF HOUSING

AND MATED HOUSING

HOUSING MATED TO HOUSING

SPIRAL RETAINER PIN(S) MUST

BE FLUSH WITH TOP AND

BOTTOM OF FRAME

ONE SPIRAL RETAINER PIN HOLE OF FRAME

MUST CONTAIN A SPIRAL RETAINER PIN FOR

EACH FORMED HOLE OF STACKED HOUSINGS

LATCHES MUST BE ENGAGED

TO LATCHING TABS

CABLE MUST NOT

BE PINCHED

HARDWARE MUST

BE SECURE

ENDS OF CABLE CLAMP

MUST BE FLAT AGAINST

FRAME

FRAMES MUST NOT BE

DAMAGED IN ANY WAY

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

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Tyco Electronics Corporation

FIGURE 21. VISUAL AID (CONT’D)

SURFACE MOUNT APPLICATION

HARDWARE MUST

BE SECURE

HOUSINGS AND MOUNTING

WINGS MUST BE FULLY

SEATED ON SURFACE

MOUNTING WINGS MUST NOT

BE DAMAGED IN ANY WAY

REQUIREMENTS FOR

HOUSING

MATED TO HOUSING

ALSO APPLY

MOUNTING WINGS

END OF MOUNTING WINGS

MUST BE EVEN WITH HOUSINGS

PANEL MOUNT APPLICATION

MOUNTING CLAMP

HARDWARE MUST

BE SECURE

HOUSINGS ARE SHOWN UNMATED

FOR CLARITY OF HOUSING

ORIENTATION (WHEN MATED,

REQUIREMENTS FOR

HOUSINGS

MATED TO HOUSING

ALSO APPLY)

MOUNTING CLAMP MUST BE

FLAT AGAINST PANEL

Power Series 15, 30, and 45 (Single-Pole) Connector Assemblies 114-13127

Rev

B22

of 22 Tyco Electronics Corporation

FIGURE 21. VISUAL AID (END)

PLUG FRAME WITH LATCHES

MATED TO PANEL MOUNT FRAME

MOUNTING FLANGE MUST

BE FLAT AGAINST PANEL

SPIRAL RETAINER PIN(S) MUST

BE FLUSH WITH TOP AND

BOTTOM OF FRAME

CABLE MUST NOT

BE PINCHED

HARDWARE MUST

BE SECURE

ENDS OF CABLE CLAMP

MUST BE FLAT AGAINST

FRAME

FRAMES MUST NOT BE

DAMAGED IN ANY WAY

LATCHES MUST BE ENGAGED

TO LATCHING TABS

ONE SPIRAL RETAINER PIN HOLE OF FRAME

MUST CONTAIN A SPIRAL RETAINER PIN FOR

EACH FORMED HOLE OF STACKED HOUSINGS