Application Specification 114-13118 Power Series 175 (Double-Pole) Connector Assembly NOTE 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 . i 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. Housing Closed-Barrel Contact Accessory Reducing Bushing (For Closed-Barrel Contact Size 1/0 Contact Cavities Marking for Marking for Positive Polarity Negative Polarity Using Small Wire Size) Wire Barrel Tab SYSTEM VOLTAGE (V) RECOMMENDED HOUSING COLOR 12 Yellow 18 Orange 24 Red 36 Gray 48 Blue 80 Black Retaining Spring Key (Position Varies) Mating Retaining Spring Face Note: Other color codes and voltage ratings are available upon request. Figure 1 E 2009 Tyco Electronics Corporation, Harrisburg, PA All International Rights Reserved TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change. PRODUCT INFORMATION 1-800-522-6752 For latest revision and Regional Customer Service, TE logo and Tyco Electronics are trademarks. *Trademark. Other products, logos, and company names used are the property of their respective owners. visit our website at www.tycoelectronics.com 1 of 9 LOC B Power Series 175 (Double-Pole) Connector Assembly 114-13118 2. REFERENCE MATERIAL 2.1. Revision Summary S 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 408-4557 408-4559 408-4561 408-8868 408-9688 408-9816 Ratcheted Cable Cutter Hand Tool 607453-2 Heavy Duty Cable Cutter Hand Tool 605742-1 Heavy Duty Cable Cutter Hand Tool 605744-1 Heavy Duty Cable Cutter Hand Tool 600769-1 Power Series 175 and 350 (Double-Pole) Connector Assemblies with Cable Clamp Kits Cable Stripper/Slitter Tool 606700-1 Handling Reeled Products 3. REQUIREMENTS 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. IMPORTANT: 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. DANGER 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. 2 of 9 Tyco Electronics Corporation Rev A Power Series 175 (Double-Pole) Connector Assembly 114-13118 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 Amines Ammonia Carbonates Citrates Nitrites Phosphates Citrates Sulfur Nitrites Sulfur Compounds 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). NOTE Wires with less than 19 strands may be too stiff and difficult to work with. i 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. CAUTION Reasonable care must be taken not to nick or scrape any part of the wire during the stripping. ! Recommended Wire Strip Length 26.4-27.6 [1.04-1.089] 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. Rev A Tyco Electronics Corporation 3 of 9 Power Series 175 (Double-Pole) Connector Assembly 114-13118 Placement of Reducing Bushing on Stripped Wire 1.52 [.060] Max Reducing Bushing to Wire Insulation Ends of Conductors Visible Wire Insulation Does Not Enter Reducing Bushing Placement of Reducing Bushing and Wire in Contact 0.38 [.015] Max Reducing Bushing to Contact Wire Barrel Contact Size 1/0 Wire and Reducing Bushing Straight in Relation to Contact Wire Barrel Figure 3 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. NOTE The developed dual-indent crimp configuration results from using the specific tooling described in Section 5, TOOLING. i 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. 4 of 9 Tyco Electronics Corporation Rev A Power Series 175 (Double-Pole) Connector Assembly 114-13118 Crimp Requirements Wire Insulation Does Not Enter Contact Wire Barrel 1.59 [.062] Max No Loose Conductors or Conductors Conductor Visible Folded Over Wire Insulation 0.38 [.015] Max Reducing Bushing (If Used) to Contact Wire Barrel Crimped Area Symmetrical on Tab Not Deformed Both Sides of Wire Barrel in Any Way A Section A-A III IIII IIII III IIII III IIII A No Flash Most Compressed Area of Wire Barrel Figure 4 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. Avoid Twist and Roll II II Crimped Portion Datum Line Uncrimped Portion Figure 5 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. Rev A Tyco Electronics Corporation 5 of 9 Power Series 175 (Double-Pole) Connector Assembly 114-13118 Up and Down Bend 2_ Datum Line 2_ Side-to-Side Bend 2_ Datum Line 2_ 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. NOTE Other key positions are available upon request. i 3.9. Installing Contacts into Housing DANGER 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: DANGER 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. NOTE Section 5 lists available extraction tools used to remove these contacts. i 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. 6 of 9 Tyco Electronics Corporation Rev A Power Series 175 (Double-Pole) Connector Assembly 114-13118 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 DANGER 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. NOTE The connector assembly meets the requirements of CSA International Standards by UL only when the cable clamps indicated in this document are used. i 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). NOTE Consult manufacturer's literature for information on using the tooling. i 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. Rev A Tyco Electronics Corporation 7 of 9 Power Series 175 (Double-Pole) Connector Assembly 114-13118 Heavy Duty Cable Cutter Hand Tool Cable Stripper/Slitter Tool Extraction Tool 68265-1 600769-1 (408-4561) 606700-1 (408-9688) (No Document) 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 Standard Insulated Screwdriver 607453-2 (408-4089) With 1 /4-in. Flat Blade Pneumatic Power Crimping Tool with Locator and Die (Commercially Available from Pico Corporation) (See Table) CRIMPING TOOL MODEL SERIES 500 DEC DIE CLOSURE DIE DIMENSION 514DA-10023 5.72 [.225] D LOCATOR 10034-1 D Die closure dimension is not crimp height dimension. If the die is dimensionally correct, the crimp height will be correct. Figure 7 8 of 9 Tyco Electronics Corporation Rev A Power Series 175 (Double-Pole) Connector Assembly 114-13118 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. WIRE INSULATION MUST NOT BE CUT OR BROKEN REDUCING BUSHING (IF APPLICABLE) MUST BE FLUSH WITH, OR PROTRUDE SLIGHTLY THERE MUST BE NO LOOSE FROM, CONTACT WIRE BARREL CONDUCTORS OR CONDUCTORS FOLDED OVER WIRE INSULATION CONDUCTORS MUST BE VISIBLE BETWEEN WIRE INSULATION MUST REDUCING BUSHING (IF APPLICABLE) OR NOT ENTER CONTACT CONTACT WIRE BARREL AND WIRE INSULATION WIRE BARREL CRIMPED AREA MUST BE SYMMETRICAL ON BOTH SIDES OF WIRE BARREL THERE MUST CONTACT MUST BE BE NO FLASH THERE MUST BE NO DAMAGE TO STRAIGHT AND NOT CONNECTORS DAMAGED IN ANY WAY CONNECTORS MUST BE FULLY MATED (HOUSINGS APPEAR FLUSH AT POINT OF ENGAGEMENT) CONTACTS MUST BE SECURE IN HOUSINGS FIGURE 8. VISUAL AID Rev A Tyco Electronics Corporation 9 of 9