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Anderson Power Products
Powerpole® & Multipole

Powerpole® & Multipole

Product catalog summary

Specifications and Tooling:
The document details the availability of high-volume automated or semi-automated crimp termination tools for reeled contacts up to 10 AWG or 6 mm². Applicators are designed to meet or exceed UL requirements, with specific tooling charts provided for recommended presses, air feed kits, and applicators for crimping each contact.

Tool Descriptions:
Includes descriptions of various applicators and presses, such as TD0101 for PP15/45 10 to 20 AWG Contacts and TE0102 for Mini-Style Applicators 230V.

Hand and Bench Tools:
Manual hand tools and pneumatic bench tools are available, covering 12 to 26 AWG capability, ensuring full cycle crimping. Specific models include TM0001, a rugged hand tool qualified to MIL-DTL-22520/1.

Crimping Best Practices:
Proper assembly instructions should be followed to avoid issues like high electrical resistance, overheating, and mechanical failures. Recommended crimp solutions are tested for performance and safety agency approvals.

Soldering Guidelines:
Soldering is an alternative to crimping, requiring careful application to avoid excess solder and overheating. A 60/40 solder with rosin flux core is recommended.

Crimp Quality Assurance:
Ensures a good crimp by using the correct wire size and type, with assembly instructions followed. Electrical resistance and pull-out strength should be tested to meet UL 486A values.

Temperature and Amperage Ratings:
Maximum amperage ratings are based on recommended tooling and wire size, considering ambient temperature. UL and CSA ratings provide guidelines for safe operation.

Temperature Charts:
Temperature rise charts show heat rise due to applied current, based on a 25°C ambient temperature. Derating charts indicate maximum amperage capability at various ambient temperatures.

Specifications:
Outlines the maximum operating temperature for connectors, typically 105°C (221°F), and provides amperage capabilities for different wire gauges at a 75°C ambient temperature.

Temperature Rise Charts:
Based on test data, these charts may differ from safety agency ratings, with CSA limiting temperature rise to 30°C above ambient and UL allowing up to 80°C rise above 25°C ambient.

Compatible Wires:
Connectors are designed for multi-stranded copper wires only, with aluminum wires not recommended due to potential galvanic reactions and mechanical issues.

Contact Technologies:
Flat wiping contacts offer low resistance and ease of assembly, while pin and socket contacts are better for compact connections but may have higher resistance.

Voltage Ratings:
Connectors are typically rated for 600V AC/DC, with testing for dielectric withstanding voltage at 2200VAC for UL approval.

Ingress Protection:
Touch safety and ingress protection ratings are provided, with IP ratings indicating protection levels against solids and liquids.

Preventative Maintenance:
Annual checks are recommended to prevent hazards, addressing issues like dirty connectors, melting housings, and damaged components immediately.

Engineering Reference:
Includes conversion charts for wire gauge to metric, volts, amps, ohms, watts, and standard to metric conversions.

Frequently Asked Questions:
Addresses common queries about connector compatibility and usage.

Specifications and Procedures:
Details on crimping multiple wires, crimp tool compatibility, metric wire usage, and voltage rating, emphasizing the use of Anderson™ tooling for optimal performance.

Design and Features:
Discusses connector mating, genderless design, color coding, and keying to prevent mismating of different voltage levels.

Safety and Standards:
Includes finger-proof housings, reducer bushings, and melting issues, with recommendations for ordering parts and accessing documentation.

Additional Information:
Crimping guidelines, soldering options, video resources, and a glossary explaining technical terms are provided.

Powerpole® Family Overview:
The Powerpole® connector series offers versatile power connection solutions with four housing sizes, accommodating up to 350 amperes per pole and wire ranges from 20 to 3/0 AWG.

Powerpole® Connector Specifications:
Details on PP15/45, PP75, PP120, and PP180 connectors, including amperage support and housing features.

Customization and Assembly:
Powerpole® connectors can be customized with various colored housings and contacts for different applications, with assembly into single or multi-row configurations.

Contact Types and Specifications:
Includes tin and silver-plated contacts, PCB contacts, and their suitability for various applications.

Overview:
Provides detailed specifications and configurations for Powerpole® 15/45 connectors, focusing on their use as durable one-piece connector headers.

Specifications:
Outlines different assembly configurations, housing types, contact types, and color coding for circuit descriptions.

Connector Housings:
Powerpole® Pak connector shells are designed to enclose stacked groupings of PP15/45 sized housings, providing a finished appearance and additional features.

Ordering Information:
Provides part numbers and dimensions for various plug shells, specifying maximum wire outer diameter for different configurations.

Temperature and Current Ratings:
Charts show derating and temperature rise at constant current for different configurations and wire gauges.

Key Recommendations:
Use APP® recommended tooling to ensure optimal performance and maintain UL and CSA recognition.

Specifications:
Details on current ratings, voltage ratings, contact resistance, material, and flammability rating for connectors.

Mechanical Specifications:
Includes wire size range, operating temperature, mating cycles, and force requirements.

PCB Specifications:
Details on mounting style, PCB thickness, and recommended traces.

IEC Information:
AMP and voltage ratings, cycle life, and temperature range.

Protection and Safety:
Touch safety and creepage/clearance specifications.

Accessories:
Includes mounting wings, spacers, retaining pins, mounting clamps, PCB mounting staples, retention clips, block lok, splash boot, and dust cover.

PP75 Series:
Applications, wire sizes, housing types, and contact specifications.

Overview:
Provides detailed technical specifications and guidelines for the Powerpole® PP75 and PP120 connectors.

Specifications:
Details on PP75 and PP120 connectors, including current and voltage ratings, wire sizes, and housing materials.

Procedures and Standards:
Temperature rise and derating charts, mechanical shock and vibration tests.

Recommendations:
Use APP® recommended tooling for optimal performance.

Accessories:
Strain relief grommets, mounting wings, and retaining pins.

Key Data from Charts:
Temperature rise and derating charts for different wire gauges.

Specifications:
Details on PP120 and PP180 connectors, including AMP and voltage ratings, cycle life, and temperature range.

Procedures:
Mounting clamps, retaining pins, and reducing bushings.

Standards and Testing:
Climatic testing, mechanical strength impact, and current-temperature derating.

Recommendations:
Use APP® recommended tooling for optimal performance.

Accessories:
Mounting clamps, retaining pins, and reducing bushings.

Key Data from Charts:
Temperature rise and derating charts for PP180 connectors.

Overview:
Provides detailed specifications and features of the MULTIPOLE FAMILY connectors by Anderson Power Products.

Key Features:
Auxiliary or ground positions, compact design, keyed and color-coded housings, low resistance connection, self-securing design, genderless housings, and hot plugging capability.

Connector Selection Guide:
Models, amps per pole, voltage rating, wire gauge, and number of circuits.

Mechanical Voltage Keys:
Molded keys prevent cross mating, with color coding corresponding to standard voltages.

SBS® Mini Connectors:
Current rating, features, and specifications.

SBS® Connectors:
Current rating, features, and housing options.

Technical Specifications:
Electrical, mechanical, and material specifications.

Overview:
Provides detailed specifications and guidelines for SBS® connectors, including the SBS® 50, 75X, and 75G series.

Specifications:
Electrical, materials, and mechanical specifications.

Procedures and Recommendations:
Use APP® recommended tooling for crimping.

Performance Charts:
Temperature rise and derating charts.

Standards and Compliance:
IEC 60529 and IEC 60512 compliance.

Additional Features:
Mounting clamps and panel mount brackets.

T-Handles for SBS® 50 and SBS® 75X:
Facilitate mating and unmating of connectors.

A-Frame Handle for SBS® 50 and SBS® 75X:
Aids in the mating and unmating process.

T-Handle for SBS® 75G:
Similar to other T-handles, made from non-conductive red plastic.

Dust Cover for SBS® 50:
Prevents dust and dirt from entering the connector's mating interface.

Cable Clamps for SBS® 50:
Securely hold cables to prevent accidental strain or dislodging.

Cable Clamps for SBS® 75X with Integral Handle:
Made from rugged chemical-resistant PBT/PC plastic.

Reducing Bushings:
Used with specific contact part numbers to allow smaller wires to be used with the connector.

SBS® Tooling Information:
Details on wire size, power/ground contacts, and auxiliary contacts.

SB® 50 Connectors:
Designed for DC power distribution and battery connections.

SB® 50 Standard and Chemical Resistant Housings:
Available in various colors and made from polycarbonate or a chemical-resistant PBT/PC blend.

SB® 50 Silver Plated Wire and Busbar Contacts:
Provide excellent electrical performance and durability.

SB® 50 Connector Specifications:
Electrical and mechanical specifications.

Specifications:
Details for SB® connectors, including SB® 50, SB® 120, and SB® 175.

Procedures:
Assembly instructions and torque values for various components.

Standards and Testing:
IEC standards for climatic testing and mechanical strength.

Environmental Protection:
Environmental boots provide protection against water, dirt, chemicals, and UV exposure.

Recommendations:
Use cable clamps to prevent accidental strain or pulls.

Accessories:
Dust covers, handles, and guide housings.

Key Data from Tables and Charts:
Part numbers, dimensions, and temperature rise charts.

Overview:
Provides detailed specifications and features of the SB® 175 and SB® 350 series connectors.

Specifications:
Wire compatibility, current and voltage ratings, temperature range, and mating cycles.

Mechanical Features:
Genderless design, material, and flammability rating.

Electrical Features:
Contact resistance and hot plugging.

Accessories:
Cable clamps, handles, dust covers, and environmental boots.

Charts and Graphs:
Temperature derating charts.

Standards and Testing:
IEC and UL standards, mechanical and environmental testing.

SB® 350 Connector Overview:
High-capacity connector designed for power applications up to 500 amps.

Specifications:
Wire size, current rating, voltage rating, dielectric withstanding voltage, operating temperature, and mating cycles.

Mechanical Features:
Contact retention force, housing material, and flammability rating.

Electrical Features:
Contact resistance and hot plug current rating.

Accessories:
Cable clamps, handles, dust cover, and lockout kit.

IEC Information:
AMP rating, voltage rating, breaking capacity, and finger safety.

Tooling Information:
Crimp tools and part numbers for different wire sizes and connector types.

Conclusion:
The SB® 350 connector is a robust solution for high-power applications.

Specifications:
Details for SBE® 80, SBO® 60, SBE® 160, and SBX® 175 connectors.

Procedures:
Assembly instructions for various components.

Norms and Standards:
International standards compliance.

Recommendations:
Use specified tooling and follow assembly instructions.

Accessories:
Auxiliary kits, air tubes, retaining pins, and zip cable straps.

Key Data from Tables and Charts:
Part numbers, minimum order quantities, and temperature rise charts.

Specifications:
Details for various components and specifications for connectors.

Accessories:
Cable clamps, handles, and auxiliary connectors.

Auxiliary Connectors:
1x4 auxiliary connector supports up to 4 circuits.

Components and Kits:
Various kits and components listed with part numbers.

Connector Specifications:
SBE® 320 and SBX® 350 connectors can handle up to 550 amps.

Electrical and Mechanical Properties:
Electrical ratings and material specifications.

Temperature and Performance:
Temperature rise charts and derating information.

Operating Temperature:
Operating temperature ranges for various housing types.

Mating Cycles:
Durability of power contacts and auxiliary connectors.

Average Mating Force:
Force requirements for main connector housing and individual connectors.

Standards and Ratings:
IEC standards for working voltage and amp ratings.

Protection and Safety:
Touch safety compliance with IEC standards.

Connector Series Configurations:
SBE® 320 creepage/clearance and material group.

Attributes:
SBE® 320 AMP and voltage ratings.

Accessories:
Cable clamps, handles, and auxiliary kits.

Auxiliary Connectors:
Powerpole® auxiliary connectors rated up to 30 amps and 600 volts.

Tooling Information:
Detailed tooling information for various wire sizes and connector types.

SB® Smart Connector:
Designed for applications where storage batteries interact with systems.

Power and Auxiliary Contacts:
Provides power up to 230 amps with signal and low power capabilities.

Sequencing and Connections:
Supports wire and busbar connections with silver-plated power contacts.

Hot Plug Capability:
Power contacts handle hot plugging up to 60A at 120VDC.

Ordering Information:
Part numbers and configurations for various applications.

Contact Specifications:
Silver-plated wire contacts offer durability up to 10,000 mating cycles.

Busbar Contacts:
Used for quick disconnect input or output connections.

Reducing Bushings:
Allow smaller wires to be used with the connector.

Auxiliary Module and Retaining Pins:
Features 8 pins and 8 sockets with retaining pins available.

Temperature and Derating Charts:
Illustrate temperature rise and current derating based on ambient temperature.

Mechanical and Electrical Specifications:
Detailed specifications include wire range, contact resistance, and retention force.

Tooling Information:
Lists tools for crimping and inserting contacts.

Catalog excerpts

Powerpole® & Multipole Connectors | 1OA up to 550A • Battery Charging • Material Handling • E-Mobility • Telecommunications • Industrial • Commercial Applications

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Global Presence Anderson Power Products® (APP®) Has a Global Distribution Network in the following countries along with many others: Argentina, Australia, Belgium, Brazil, Canada, Chile, China, Columbia, Denmark, France, Germany, Greece, Hong Kong, Ireland, Israel, Italy, Japan, Mexico, New Zealand, Norway, Peru, Poland, Portugal, Singapore, Slovenia, South Africa, South Korea, Spain, Switzerland, Thailand, Turkey, United Kingdom, India and United States. Our philosophy is to provide products and services within the trading markets of our customers. We currently serve our worldwide customer base...

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Powerpole® & Multipole Catalog All Data Subject To Change Without Notice

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PRODUCT SELECTOR Product Selector Guide How to Use This Catalog The information in this catalog is provided in layers to allow you to quickly find the information you are looking for. 1. Selection Guides are featured at the front of the catalog and at the beginning of each product section to enable quick connector selection by electrical attributes and other features. 2. A Technical Reference is provided to give important information common to all connectors in this catalog. Answers to common questions, definitions of terminology, and technical charts are all included. 3. Overviews at the beginning...

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PRODUCT SELECTOR Product Selection Worksheet Prior to selecting an interconnect solution, we recommend you gather the following information. This will aid you in quickly identifying the best product for your particular need. Amps Continuous ________________ Peak _____________________ Max AMPS ___________ Volts Max AMPS ___________ Seconds Circuit Definition Number of Circuits: Power ____________________ Ground ____________________ Auxiliary____________________ Other ____________________ Application □ PCB-to-PCB □ Wire-to-Panel Mounting Method - If Applicable □ PCB □ Panel Contacts □ Mating Cycles...

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Anderson™ Tooling Why Use of Anderson™ Recommended Tooling is so Important Our connectors are designed to achieve the highest levels of durability, reliability, and performance as shown on the connector data sheets. Crimp tooling is a critical link between the designed performance of a connector and the realization of that performance by our customers. As part of the connector design and testing process, we recommend a number of crimp solutions that have proven to deliver the intended connector performance in a process that is repeatable. Only these solutions tested by us are listed in the conditions...

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1387G1 & G2 Pneumatic Bench Tools Versatile & heavy duty tools manufactured by Pico Tools, use fixed depth dies and spring bottom locators designed specifically to crimp our contacts. Dies and locators are not interchangeable between the 1387G1 and the 1387G2. These pneumatic full cycle tools operate on clean and dry shop air pressures of 80 - 125 psi (5 - 8.6 BAR). See connector family tooling charts at the end of each section for the specific dies and locators recommended for crimping each contact. Dies and locators are available from Pico Tools for a variety of other terminal types including...

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1309 Series Hand Tools High quality hand tools are designed for crimping 6 to 20 AWG (13.3 to 0.52 mm2) wires for Powerpole®, SB®, SBS®, and SBE® / SBO® connectors. The extra long bright yellow handles provide significant crimping force while minimizing operator fatigue. Full cycle ratchet mechanism makes sure every crimp is fully completed. All tools except 1309G4 include a plastic locator piece that ensures proper positioning of the contacts for crimping. 1309G2: For crimping PP15/45 loose piece strip contacts and individual contacts. 16 to 20 AWG (1.3 to 0.5 mm2) 12 to 20 AWG (3.3 to 1.3 mm2)...

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MIL-SPEC Hand & Bench Tools Manual hand tools and pneumatic bench tools are available in this tool series. The hand and pneumatic tools both use the same turret locators designed specifically for APP® contacts. The interchangeable nature of the turret locators allow easy upgrades from prototyping to production volumes. All tools feature adjustable indenter depths to cover 12 to 26 AWG (3.3 to 0.25 mm2) capability. Full cycle mechanism makes sure every crimp is fully completed. See tooling charts at the end of each connector section for the appropriate turret locator part numbers. TM0001: Rugged...

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Crimping Technical Reference Crimping, Soldering, and Assembly Best Practices. Instructions for proper assembly are available for each connector and should be followed. These best practices are for reference only. Stripping Wire Insulation Problems with cable harness and connector systems often begin with improper or accidental cutting of wire strands when stripping wire insulation. Each strand is important, and all of them must be included in the contact barrel to avoid unnecessary hot spots during later operation. When removing insulation, position a sharp blade at a right angle and apply a...

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Soldering The alternative to crimping is to solder all cable strands within the contact barrel. When using an open flame, make sure that you are not in an area where explosive gasses are present. The right proportion of solder is essential if this procedure is employed. Use a quality 60/40 solder (60 percent tin, 40 percent lead) in wire form with a rosin flux core. Cable strands should be separately fluxed with rosin paste, and the contact should be held in a vise with the barrel end facing up. Apply heat to the outside of the barrel while the solder flows in beside the wire strands. Here are...

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Why Crimp Dimensions are not Suitable as Primary Inspection Criteria Crimp dimensions are not an adequate or reliable means to evaluate if a good crimp has been made. For this reason they should not be relied upon as a primary inspection method. When you crimp a contact, the material is forced down to the size of the fully closed die. This die closure on most tools is a fixed dimension. When the die is released, the material (contact and wire) will expand back out when they are no longer restrained by the die. The amount that it expands outwards or “bounces back” is dependant on the resistance...

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