Anderson Powerpoles Rene “Ren” Ramirez A.R.S. W3BNY

Anderson PowerpolesAnderson Powerpoles

Rene “Ren” RamirezRene “Ren” Ramirez

A.R.S. W3BNYA.R.S. W3BNY

Basic Safety NoticeBasic Safety Notice

THINK ELECTRICAL SAFETY! (even THINK ELECTRICAL SAFETY! (even when not working with electricity!)when not working with electricity!)

Basic Tool Safety (right tool…)Basic Tool Safety (right tool…) PPE! You only have one set of eyes!PPE! You only have one set of eyes! Trust the little voice in your head…if what Trust the little voice in your head…if what

you are doing feels un-safe,you are doing feels un-safe,IT PROBABLY IS!IT PROBABLY IS!

If in doubt, ask. And If really If in doubt, ask. And If really confuzzled/perpelexed…confuzzled/perpelexed…

Anderson PowerpolesAnderson Powerpoles Invented by Anderson Power

Products Wide Product Range

I=15 through 310 amps V=600VAC/DC

Silver Plated Contacts Offers greatest longevity when

using high power, elevated temperature applications

Flat Wiping Contact System Allows for minimal contact

resistance at high current, wiping action cleans contact surface during connection/disconnection

Anderson Powerpoles (continued)Anderson Powerpoles (continued) Colored Modular

Housings Provides visual

identification of proper mating connector

11 different colors! Molded-in Dovetails

Secures individual connectors together

Interchangeable Genderless Design

Polarized Housings Prevents damage to

connectors (and equipment) from being mated incorrectly

Anderson Powerpoles (continued)Anderson Powerpoles (continued)

Standard for ARES/RACES

equipment and teams!

Powerpole IdentificationPowerpole Identification

4 different sizes4 different sizes PP15/30/45PP15/30/45 PP75PP75 PP120PP120 PP180PP180 Only PP13/30/45 are Only PP13/30/45 are

interchangeable. All interchangeable. All others are not!others are not!

Powerpole parts breakdownPowerpole parts breakdown

1.1.HousingHousing

2.2.ContactsContacts

3.3.Lock pinLock pin

PP 15/30/45 DifferencesPP 15/30/45 Differences

15/30- Only difference 15/30- Only difference is the size of the wire is the size of the wire barrel on contactbarrel on contact

45-Style of wire 45-Style of wire mount is different mount is different than the 15/30than the 15/30

When connected, When connected, hard to distinguish hard to distinguish other than wire gauge other than wire gauge used. used.

Powerpole ConstructionPowerpole Construction(for Amateur radio)(for Amateur radio)

Tools and suchTools and such

Powerpole assembly toolsPowerpole assembly tools

Three basic tools neededThree basic tools needed

1.1. Wire cuttersWire cutters

2.2. Wire strippersWire strippers

3.3. Contact crimperContact crimper**

One sundry itemOne sundry item

1.1. CA adhesive (aka crazy glue)CA adhesive (aka crazy glue)

Wire cuttersWire cutters

Nothing fancy.Nothing fancy. Good and sharpGood and sharp Appropriate to gauge Appropriate to gauge

of wire your using.of wire your using.

Wire StrippersWire Strippers

Good and sharpGood and sharp Appropriate to gauge Appropriate to gauge

of wire your using.of wire your using. Y.G.W.Y.P.F!Y.G.W.Y.P.F!

Contact crimperContact crimper

Contact crimperContact crimper

Heart of the procedure!Heart of the procedure! Mess this up and you’ve botched the Mess this up and you’ve botched the

whole thing (contact wont lock in or whole thing (contact wont lock in or worse…WIRE CAN COME OUT)!worse…WIRE CAN COME OUT)!

Three different styles.Three different styles.

1.1. NoNo

2.2. ZOMG!!1ZOMG!!1

3.3. Just Right!Just Right!

Contact crimpers (NO!)Contact crimpers (NO!) Guaranteed to mess upGuaranteed to mess up Inconsistent resultsInconsistent results Inexpensive…$12.99Inexpensive…$12.99

Overall rating, MEH Overall rating, MEH

Contact crimpers (ZOMG!)Contact crimpers (ZOMG!)

Consistent results!Consistent results! Official APP crimperOfficial APP crimper Only does 30 and Only does 30 and

45A contacts45A contacts

$219.99!$219.99!ZOM*GZOM*G

Contact crimpers (Just right!)Contact crimpers (Just right!)

West Mountain Radio West Mountain Radio crimpercrimper

Consistent resultsConsistent results Does 15, 30 and 45A Does 15, 30 and 45A

contacts!contacts!

$39.95!$39.95!

Contact crimpers (Just right!)Contact crimpers (Just right!)

Assembly proceduresAssembly procedures

Shell selectionShell selection

Remember, 11 Remember, 11 different colorsdifferent colors

Red BlackRed Black Blue GreenBlue Green White OrangeWhite Orange Yellow GreyYellow Grey Brown VioletBrown Violet PINK!PINK!

Shell selectionShell selection(For AMATEUR RADIO FOLKS)(For AMATEUR RADIO FOLKS)

Yes Virginia, there is an standard color Yes Virginia, there is an standard color code.code.

ARES/RACES uses red/black to indicate ARES/RACES uses red/black to indicate +12vdc.+12vdc.

Industrial powerpoles (SB series) have an Industrial powerpoles (SB series) have an industry standard color scheme.industry standard color scheme.

BE VERY CARFULL when mating to BE VERY CARFULL when mating to non amateur power sources!non amateur power sources!

ASK FIRST or CRY laterASK FIRST or CRY later



RED +12vdc +12vdc BLACK Return Return Any other Any other

combinationscombinations YOU BETTER YOU BETTER

DOCUMENT IT!DOCUMENT IT!

Shell assemblyShell assembly

Shell orientation Shell orientation VERY important.VERY important.

As you are looking at As you are looking at the connector.the connector.

1.1. Tongues upTongues up

2.2. ““A”s upA”s up

3.3. Black on leftBlack on left

4.4. Red on rightRed on right


Locking pins...Locking pins... THROW THEM THROW THEM

AWAY OR AWAY OR RECYCLE!RECYCLE!

Chances of pin Chances of pin coming out under coming out under vibration very goodvibration very good

Steel and electricity Steel and electricity not good partners.not good partners.

Just glue it!Just glue it!


Get correct Get correct orientation.orientation.

ONE DROP of CA ONE DROP of CA (don’t need much) on (don’t need much) on the inside dovetailthe inside dovetail

QUICKLY and with a QUICKLY and with a little force, slide them little force, slide them together till they are together till they are both levelboth level

DONE!DONE!

Contactor SelectionContactor Selection 15/30/45 What is the 15/30/45 What is the

wire size?wire size? 15 20~16ga15 20~16ga 30 16~12ga30 16~12ga 45 14~10ga45 14~10ga Over size them? Over size them?

(lower current on (lower current on bigger size?) Sure!bigger size?) Sure!

Under size them? Under size them? (over current range)(over current range)….….

Contactor assembly.Contactor assembly.

1.1. Square off the wire endsSquare off the wire ends2.2. Split conductors back about ½ inch.Split conductors back about ½ inch.3.3. Strip conductors back approximately 5/16 inch.Strip conductors back approximately 5/16 inch.4.4. If stranded, twist the bundle tightIf stranded, twist the bundle tight5.5. NO NEED TO TIN!NO NEED TO TIN!6.6. Insert conductor into contactor. Should be Insert conductor into contactor. Should be

flush and wire should barely be seen on front flush and wire should barely be seen on front of contactor.of contactor.

7.7. Verify that there isn't an excess amount of Verify that there isn't an excess amount of conductor exposed at end of contactor. It conductor exposed at end of contactor. It should be almost if not flush with insulationshould be almost if not flush with insulation

Contactor assembly continued.Contactor assembly continued.

Insert contactor “curve” down into crimper.Insert contactor “curve” down into crimper. Give one or two clicks to hold contactorGive one or two clicks to hold contactor Re-insert wire if necessaryRe-insert wire if necessary FIRMLY SQUEEZE handle all the way thru the FIRMLY SQUEEZE handle all the way thru the

cycle and release.cycle and release. Conductor done!Conductor done! One note: The 45A contactor. You may need to One note: The 45A contactor. You may need to

squeeze the wire crimp wings just a bit to get it squeeze the wire crimp wings just a bit to get it to a “U” shape to fit the crimper.to a “U” shape to fit the crimper.

Should look just like this!Should look just like this!

These are acceptable too!These are acceptable too!

P.S. This is also the correct orientation for P.S. This is also the correct orientation for insertion into a correctly coded powerpole insertion into a correctly coded powerpole

shell!shell!

INCORRECT examplesINCORRECT examples

Contacts at odd Contacts at odd angle.angle.

Twist them gently to Twist them gently to correct orientation.correct orientation.


Contact blades bent.Contact blades bent. Gently straighten Gently straighten

them up.them up.


WRONG WRONG ORIENTATION!ORIENTATION!

Flip wire and gently Flip wire and gently twist conductors to twist conductors to match connector.match connector.

CORRECT examplesCORRECT examples

Contacts straightContacts straight Contacts correctly Contacts correctly

alignedaligned Contacts correctly Contacts correctly

polarizedpolarized Ready to insertReady to insert

Final connector assemblyFinal connector assembly

Insert contactor “curve” down towards the Insert contactor “curve” down towards the tongue (A).tongue (A).

Slide straight in until “CLICK” is heard or Slide straight in until “CLICK” is heard or felt.felt.

Tug back on conductor to verify lockTug back on conductor to verify lock Repeat with other conductor.Repeat with other conductor. DONE! One powerpole completed!DONE! One powerpole completed!

Cutaway showing contactor locked Cutaway showing contactor locked into connectorinto connector

OOPS! I goofed up, or I need to OOPS! I goofed up, or I need to remove the wire/conductor. remove the wire/conductor.

What do I do?What do I do?

Contactor removalContactor removal

A special APP tool is available to help remove A special APP tool is available to help remove the contactor from the shell.the contactor from the shell.

A jewelers flat blade tweaker is also probably A jewelers flat blade tweaker is also probably available in your tool box that will do the same available in your tool box that will do the same thing!thing!

Procedure is to put the blade just under the Procedure is to put the blade just under the contactor curve and lift up while pulling on the contactor curve and lift up while pulling on the conductor. When the curve is clear, the conductor. When the curve is clear, the conductor will pull right out.conductor will pull right out.

(Kinda clunky first time you do it but it does (Kinda clunky first time you do it but it does work!)work!)

Contactor removalContactor removal

Lift this up!

Pull on this!

FAQ’sFAQ’s

““I’m using 15A connectors and the wire is just I’m using 15A connectors and the wire is just too small. What do I do?”too small. What do I do?”

Easy, double it then crimp it!Easy, double it then crimp it! ““The wire fits better in the 30A or the 45A The wire fits better in the 30A or the 45A

connector but the widget is only drawing 10 connector but the widget is only drawing 10 amps. Can I use the higher capacity contactor?”amps. Can I use the higher capacity contactor?”

You sure can! Nothing says you can’t use a You sure can! Nothing says you can’t use a higher ampacity contactor. Just don’t go lower!higher ampacity contactor. Just don’t go lower!

““I’m not going to double the wire. That’s just I’m not going to double the wire. That’s just now how I roll. Any other options?”now how I roll. Any other options?”

There sure is shippy…There sure is shippy…

FAQ’s continuedFAQ’s continued

Reducing bushings!Reducing bushings!

FAQ’sFAQ’s

““I don’t crimp anything. Rosin runs in my blood I don’t crimp anything. Rosin runs in my blood and I keep a strand of 60/40 in my pocket at all and I keep a strand of 60/40 in my pocket at all times! Can I solder these puppies?”times! Can I solder these puppies?”

Yes you can, but don’t bubble-gum it or use a Yes you can, but don’t bubble-gum it or use a piece of rebar to solder the thing. And don’t flow piece of rebar to solder the thing. And don’t flow too much up the wire to harden it. Less is more too much up the wire to harden it. Less is more and beware of not melting the insulation!and beware of not melting the insulation!

““I’m a non-standard type-o-guy and none of my I’m a non-standard type-o-guy and none of my installations are standard…can these things installations are standard…can these things make a non-standard configuration?”make a non-standard configuration?”

Yes they can! Use your imagination Yes they can! Use your imagination and document your work!and document your work!

Some neato accessories for your Some neato accessories for your new powerpole familynew powerpole family

Oh…and who said that Powerpoles Oh…and who said that Powerpoles were just for power distribution. were just for power distribution.

Some VendorsSome Vendors

PowerWerx (PowerWerx (www.powerwerx.comwww.powerwerx.com)) West Mountain Radio (West Mountain Radio (

www.westmountainradio.comwww.westmountainradio.com))

Questions?Questions?

Documents

Anderson Powerpoles Rene “Ren” Ramirez A.R.S. W3BNY