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Tongue-and-groove dovetailing in the connector housings allows the cases to be connected snugly to each other.
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Three contact sizes are intended for use with different wire gauges. The sizes are officially named for applications in building construction that assume 110 volts, so don’t be misled by the names. Left to right: The “45 amp” pin (#261G2) is for 10–14 gauge wire; the “30 amp” pin (#1331) is for 12–16 gauge wire; and the “15 amp” pin (#1332) is for 16–20 gauge wire. Once installed in connector housings, these different size pins snap together perfectly on the contact side.
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Close-up of a 30 amp pin before crimping.
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The crimped pin has been bent straight by hand. This will ensure proper mounting in the housing, which in turn will ensure the right “pin float” in the connector housing, and that, in turn, provides the best connector connection.
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Detail views of a properly crimped pin.
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To avoid a bunched crimp, which occurs when the pin is placed too deeply in the die cavity, mount the pin flush with the exterior face of the crimp jaw and apply just enough pressure to hold the pin, and then insert the wire and crimp. Shown is a 30 amp pin. The 45 amp pin die on the right (see arrow) is slightly recessed: when crimping a 45 amp pin, its base should be flush with the recessed exterior surface of the die. Before crimping a 45 amp pin, bend the ears on the end slightly
together by hand to ensure proper folding in the crimper.
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Be careful when opening the jaws to ensure that the contact is not stuck in the top die. If it is, stop opening the handle and push the contact out with a small screwdriver as shown. Tap it with a pair of pliers or small hammer, and the pin will fall free and the crimper will open on its own. Factors that can contribute to pin-sticking include the type of wire, condition of the dies, handle release tension and the contacts themselves. Keep the dies clean by rubbing the inside of the die with steel wool or Scotch-Brite to minimize sticking, or contact West Mountain Radio for assistance regarding stick pins. |
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Housings can be joined with contacts rotated in different directions to ensure plug compatibility.
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The PWRcrimp Crimp Tool, offered at www.westmountainradio.com for $49.95, crimps all three sizes of pins.
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The contact in the foreground has been crimped. The “spoon” component of the contact extends in a straight line; this angle must be maintained for proper mounting of the housing. If they are bent slightly upward they may not stay in the housing; bent down they do not mate with full force.
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This pin has been crimped; notice that the contact portion has been bent slightly downward in the crimping process. A slight downward or upward bend can occur depending on the wire size you are using for a given pin. This is normal—the secret is to bend the pin back to align it parallel with the crimped
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Cutaway view shows steel springs that hold the contacts in place. The contact portion of the pins must be straight (not bent) for proper locking of the connectors. When you mount the pin in the housing, push the pin in by hand or with the help of a small screwdriver till you hear it “click” as the pin snaps in place over the spring. If you feel a few thousandths play side-to-side and about 1/32-in. when you jiggle the wire, you’ve done it exactly right: that is “pin float” and it will enable the pin to seat perfectly. You will hear a crisp snap when a properly assembled connector is connected to another Powerpole. It’s good for 10,000 connects and disconnects!
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Note that the end of the crimped portion has slightly bunched up. This is not a properly crimped pin.
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If a pin “sticks” in the upper seat of the crimping jaw and you open the crimper fully, the die cavity will bend the front of the pin down, as shown, which will likely ruin the pin.
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You are already using other connector types? No worries, you can quickly and easily make patch cords to ensure cross compatibility for all your electric flight options. You can easily make parallel circuit patch cords (for flying with 2P lithium setups), and you can easily connect two batteries in series using Powerpoles. Few connector systems offer the ease of use of Anderson Powerpoles. To order a crimper, connectors, pins and housings, contact West Mountain Radio.
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