Powerpole Modular Connector Assembly Sheet For installation by a qualified electrician in accordance with national and local electrical codes and the following instructions. The suitability of this type of termination must be evaluated by Underwriters Lab- oratories, Inc. and Canadian Standard Association for the end use application. Assemble contact to the cables according to the equipment manufacturers assembly instructions. The following instructions are supplied as a reference. Please Note: Instructions are included with each crimp tool for terminating specific contacts. Use of non-Anderson Power crimp can effect UL & CSA approval. See website for comprehensive tooling data. Powerpole Housing Bushing Series Series Contact AWG mm Number 15 1395 1332 20 - 16 0.5 / 1.0 N/A 30 1330 1331 16 - 12 1.0 / 2.5 N/A 45 1845 1830G1 14 - 10 1.5 / 4.0 N/A 45 1345 261G2 14 - 10 1.5 / 4.0 N/A 75 1300 5900 16 - 14 1.0 / 1.5 5913 75 1300 5900 12 - 10 2.5 / 4.0 5910 75 1300 5915 12 - 10 2.5 / 4.0 N/A 75 1300 5900 8 6 5912 75 1300 5900 6 10 N/A 75 1300 5952 8 6 N/A 75 5927 1875G1 6 10 N/A 75 5927 1875G2 8 6 N/A 75 5927 1875G3 12 - 10 2.5 / 4.0 N/A 120 1320 1319 8 6 5921 120 1320 1319 6 10 5920 120 1320 1319G6 6 10 N/A 120 1320 1319 4 16 5919 120 1320 1319G4 4 16 N/A 120 1320 1319 2 25 N/A 120 1320 1323G1 1 35 N/A 120 1320 1323G2 1/0 50 N/A 180 1380 1382 10 4 5648 180 1380 1382 6 10 5663 180 1380 1348* 6 10 N/A 180 1380 1382 4 16 5693 180 1380 1384 4 16 N/A 180 1380 1382 2 25 5690 180 1380 1383 2 25 N/A 180 1380 1382 1 35 5687 180 1380 1347 1 35 N/A 180 1380 1382 1 50 N/A 180 1380 1328G1 2/0 70 N/A 180 1380 1328G2 3/0 95 N/A ASSEMBLY INSTRUCTIONS Connector 1. Strip wire to X dimension (Figure 1) Series AMPS inches mm taking care to avoid nicking or cutting 1395 Series 15 5/16 7.9 of wire strands. Do not bend or twist 1330 Series 30 5/16 7.9 strands too sharply. 1845 Series 45 5/16 7.9 1345 Series 45 5/16 7.9 1300 Series 75 9/16 14.5 1320 Series 120 15/16 24 Figure 1 1380 Series 180 1 - 1/8 28.6 TERMINATION 2. Manufacturer recommends termination by crimping. a. Crimped 1300, 1320 and 1380 series contacts accept largest wire sizes rated. Smaller wire sizes require reducing bushings, Cat. Numbers 1395, 1300, 1845 and 1345 do not require reducing bushings. Insert wire to the base of contact, then crimp. Note: indentation should fall in the middle of the barrel (see Figure 2). Use recommend crimp tools only. Crimping by other means may disturb contact position in housing and/or produce high resistance joints. Crimp Figure 2 b. Soldered Melt rosin flux tin solder into contact well, do not solder-dip contacts or overload the joint with solder. On 1395 and 1300 Series contacts, solder flow should not extend beyond contact wall. On all models, care should be taken that no solder adheres to contact surfaces.CONTACT INSERTION Insert contact and wire into the housing from the rear (See Figure 3). Position contact as shown (See Figure 4) and push forward using insertion / extraction tool Cat. Number 111038G2 for smaller wire sizes in 1345, 1395, 1330, 1845, 1300 models so that contact slips under the barrier and snaps over the end of the retaining spring (See Figure 5). Tug slightly to make sure contact is locked in place. Figure 3 Figure 4 Figure 5 (cut away) Powerpole Connector Wire Size Tool Part Crimping Tool (1) Rating (amps) AWG mm Numbe r Manual, cycle controlled F-type 1309G6* 10 16-12 1.5-4.0 1309G1 crimping tool Manual, cycle 15-30 20-12 0.5-4.0 1309G2 controlled F-type 1309G6* crimping tool Pneumatic, cycle 15-30 20-12 0.5-4.0 1367G1 controlled F-type crimping tool Manual, cycle 45 14-10 2.0-6.0 1309G3 controlled F-type 1309G6* crimping tool Manual, cycle 75 16-12 controlled U-type 4.0-16.0 1387G1 crimping tool Pneumatic, cycle 75 12-6 4.0-16.0 1387G1 controlled 4-indent crimping tool Pneumatic, cycle controlled 4-indent amps 120 or 180 3/0- 10 95-6.0 1387G1 crimping tool Hydraulic, noncycle 120 or 180 3/0- 10 95-6.0 1368 controlled 4-indent amps crimping tool * For use with superflex wire Notes 1. Use appropriate reducing bushings for smaller cable sizes. 2. For appropriate crimping die set, see APP website tooling chart. 3. For high volume crimping (reeled contacts), see APP website tooling chart. CONTACT REMOVAL Switch off power first. For 1320 and 1380 series select a screwdriver of appropriate size. Depress spring at front of housing and pull wire out. For 1395, 1330, 1845, 1345 and 1300 series, insertion / extraction tool (Number 111038G2). Place one of the forward prongs of the tool between the contact and spring using a rotary motion. Continue rotation while pulling on the wire until the prong causes disengagement of contact from the spring. Withdraw contact from rear of housing (See Figure 6) Figure 6 CONNECTOR USAGE 1. Do not disconnect under load. Not for interrupting current. 2. Connector halves should not be disconnected by grasping cable leads. 3. For use only in equipment where the acceptability of the combination is determined by UL / CSA or other applicable certification agencies and installed by a qualified electrician. Hood Up Figure 7 BLOCKING 1. Hold connector side-by-side in the hood up position. 2. Slide the protruding dovetail into the recessed dovetail slot. Slide (See Figure 7) Forward 3. Blocking is completed when the front and back of the connectors are even with eachother. (See Figure 8) Figure 8 NOTE: Do not use a hammer to slide connectors together. Even Even PATENT & TRADEMARK INFORMATION Patent information can be found on our website. Powerpole and Anderson Power Products are registered U.S. and foreign trademarks of Anderson Power Products. www.andersonpower.com 1S1072 15860, REV 14