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 6
Using Small Wire Size)
Application Specification
Power Series 350 (Double-Pole) 114-13119
LOC B
1
of 9
E
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
12 MAR 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 350 (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, 2/0, 3/0, 4/0, and 300 and accept wire sizes (AWG) that
correspond to the contact size. Reducing bushing is available for contact size 2/0 to accommodate wire size
1/0 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
72 Green
NOTE
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2. REFERENCE MATERIAL
2.1. Revision Summary
Revisions to this application specification include:
S
Updated document to corporate requirements
S
Added Figure 7
2.2. Customer Assistance
Reference Product Base Part Number 1604050 and Product Code H416 are representative of Power Series
350 (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:
408–4557 Heavy Duty Cable Cutter Hand Tool 605742–1
408–8868 Power Series 175 and 350 (Double–Pole) Connector Assemblies with Cable Clamp Kits
408–9816 Handling Reeled Products
408–9688 Cable Stripper/Slitter Tool 606700–1
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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Tyco Electronics Corporation
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, 2/0, 3/0,
4/0 AWG, and 300 thousands circular mils (MCM) with a maximum insulation diameter of 27.94 [1.10]. Contact
size 2/0 can accept wire size 1/0 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.
33.0-34.3
[1.3-1.35]
Recommended Wire Strip Length
Note:
Not to Scale
Figure 2
3.6. Reducing Bushing
Reducing bushing is available for contact size 2/0 to accommodate wire size 1/0 AWG. When required, the
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
i
CAUTION
!
Power Series 350 (Double-Pole) Connector Assembly 114-13119
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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 2/0
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
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Power Series 350 (Double-Pole) Connector Assembly 114-13119
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Tyco Electronics Corporation
ÏÏÏÏ
ÏÏÏÏ
ÏÏÏÏ
ÏÏÏÏ
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
Crimped Area Symmetrical on
Both Sides of Wire Barrel
Tab Not Deformed
in Any Way
Figure 4
ÌÌÌ
ÌÌÌ
ÌÌÌ
Most Compressed Area
of Wire Barrel
0.38 [.015] Max
Reducing Bushing (If Used) to Contact Wire Barrel
Section A-A
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
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.
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.
NOTE
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Power Series 350 (Double-Pole) Connector Assembly 114-13119
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Figure 6
Up and Down Bend
Side-to-Side Bend
Datum Line
Datum Line
2
_
2
_
2
_
2
_
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 (shown in Figure 7).
1. Each contact must be inserted into the wire side of the housing.
2. The bottom of each contact must face the retaining spring of the housing (the word “AMP” or TE logo
marked on the connector and on the contact must be facing the same direction).
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 retaining 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.
2. The handle of the tool must be pushed down so that the housing retaining 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.
DANGER
DANGER
NOTE
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Tyco Electronics Corporation
Figure 7
AMP" Marking or TE Logo
AMP" Marking or TE Logo
AMP Marking or TE Logo
AMP Marking or TE Logo
Installing Contacts Into Housing
Wire Side of
Housing
Retaining
Spring
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 350 (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 8.
DANGER
NOTE
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Power Series 350 (Double-Pole) Connector Assembly 114-13119
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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.
Extraction Tool 68265-1
(No Document)
Heavy Duty Cable Cutter Hand Tool
605742-1 (408-4557) 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 WIRE SIZE DIE DIE CLOSURE
DIMENSION
D
LOCATOR
300 MCM 514DA-10027 12.06 [.475]
4/0 AWG 514DA-10026 10.16 [.400] 10023-2
500 DEC 3/0 AWG 514DA-10025 9.14 [.360]
2/0 AWG 514DA-10024 8.26 [.325]
10023 1
1/0 AWG 514DA-10023 5.72 [.225]
10023
-
1
Figure 8
D
Die closure dimension is not crimp height dimension. If the die is dimensionally correct, the crimp height will be correct.
NOTE
i
Power Series 350 (Double-Pole) Connector Assembly 114-13119
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Tyco Electronics Corporation
6. VISUAL AID
The illustration below shows a typical application of Power Series 350 (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 9. 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
