High Current Products Catalog Revised 4-01

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2 Product Facts Pins and sockets have low insertion force High current ratings with very low resistance All plated products are gold or silver plated Louvertac bands have a temperature range from 196 C to +200 C available Formed bands are available for up to [31.75] pin diameter 65 POSITION AMPOWER MULTI PIN PLUS PLUG AND RECEPTACLE Interfaces The transfer of high curre n t with manageable insert i o n and withdrawal forces has always presented a challenge to the connector industry. L o u v e rtac bands provide a unique means of transferring high amperage with a resultant space and weight savings. Tyco Electro n i c s Corporation offers a wide THREAD MOUNT PIN IS INSTALLED DIRECTLY INTO POWER SUPPLY range of pin and socket sizes for your applications. Strip and formed Louvert a c bands are also off e red for customer use in their own contact design. The wide variety of flat and form e d male and female bands p rovide the ability to design electrical connections more inexpensively and quickly. MATE-N-LOK II CONNECTOR WITH HIGH CURRENT CONTACTS L o u v e rtac products are your high current applications s o l u t i o n. The variety of pins and sockets available from Ty c o E l e c t ronics Corporation p rovide a quick and simple solution to most high curre n t a p p l i c a t i o n s. TYPICAL APPLICATION OF LOUVERTAC STRIP 35 POSITION AMPOWER MULTI PIN PLUS PLUG AND RECEPTACLE THREAD MOUNT PIN ASSEMBLY WITH AMP TERMINAL Metrimate DRAWER CONNECTOR WITH HIGH CURRENT CONTACTS CRIMP PIN WITH CABLE INSTALLED , 1993, 1995, 1997, 1998 and 2001 by Tyco Electronics Corporation. All Rights Reserved. AMP, AMPLIMITE, AMPOWER, DYNA-CRIMP, LGH, M ATE-N-LOK, and TYCO are trademarks. Other products, logos, and Company names mentioned herein may be trademarks of their respective owners. THREAD MOUNT SOCKET IS INSTALLED DIRECTLY INTO POWER SUPPLY THREADED SLEEVE SOCKET A S S E M B LY IS INSTA L L E D D I R E C T LY INTO P OWER SUPPLY

3 Support Services Answers to your q u e s t i o n s a re just a phone call or mouse click a w a y. On-Line Catalog If you prefer to find your information electronically, check out our web site featuring a catalog containing over 135,000 products. Customer drawings, specifications, test reports, CAD models and electrical SPICE models, PCB layouts and panel cutouts can be downloaded from the web site. Cross references to hundreds of competitors makes it even easier to find the right part for nearly any application. Technical Support Center /help Our Technical Support Specialists provide information on distributor locations, drawing/prints, application/product specifications, PCB layouts, technical information, plating, electrical characteristics, dimensions, value added capabilities, and 3D modeling/simulation. Tooling Assistance /help Tooling support specialists will assist you in selecting hand tools, machines and applicators, identify tooling parts, and provide information about maintenance, adjustment and repair. Customer Service /help Receive price and delivery information immediately. You can also place new orders, change or expedite existing orders, and request product samples and literature through the Customer Service Department. AMP FAX Service Documents available through AMP FAX include part numbers/catalog pages, drawings, application/product specifications, PCB layouts, and distributor information. Order as many as 20 pages of information at a time, with more than 100,000 drawings, specs, and more available M LUG DSP G3B Printed in U.S.A. 39 Tyco Electronics Corporation, Harrisburg, PA 17105

4 Table of Contents Interfaces Thread Mount Socket and Pin Assembly Threaded Sleeve Socket Assembly and Application Crimp Pins Crimp Sockets High Current Upgrade Program Metrimate Drawer Connector Contacts, Size Universal MATE-N-LOK II Connectors , 10 Type XII Contacts Size 16, Type II and Type III+ Contacts Size 20 Posted Contacts AMPOWER Multi Pin Plus Connectors Standard 2-, 3-, 4- and 8-Position Modules Standard 65-Position Standard 35-Position Position Position Position and 28-Position , Position and 11-Position Position mm Pin and Socket Crimp Contacts mm Thread Mount Pin and Socket Contacts mm Pin and Socket Crimp Contacts mm Solder Tail Pin and Socket Contacts Type III+ Signal Posted Contacts mm Hot Mate Pin and Socket Multimate Pin and Socket Contacts Type III+ Crimp Contacts High Current Size 16 Contacts and Solder Tail Pin Connector Mounting Options Contact Sequential Mating Cycle Fork Connectors Louvertac Strip, Torsional Louver Type Louvertac Strip, Bridge Louver Type Preformed Female Louvertac Bands Preformed Male Louvertac Bands , 36 Part Number Index Need more information? Call the Technical Support Center: The Center is staffed with specialists well versed in all AMP products. The Center can provide you with: Technical Support Catalogs Technical Documents Product Samples Authorized Distributor Locations 3

5 Thread Mount Socket and Pin Assembly Thread Mount Sockets These sockets are designed for easy installation and removal. The large variety of sizes have ratings from 30 continuous amps and can be mated with Thread Mount Pins and Crimp Pins. Body Brass Louvertac Band Beryllium Copper Body Silver Louvertac Band See Table Contin. Voltage Dimensions Louvertac Mating Part Thread Current Drop A B C D E F Band Pin Dia. Number (Amp) (mv) Dia. Dia. Ref. Plating 2 mm M3x Silver 4 mm Gold 6 mm / Gold 8 mm / Silver Thread Mount Pins These pins are designed for thread mount. The large variety of sizes have ratings from 30 continuous amps and are designed to be mated with Thread Mount Sockets, Threaded Sleeve Sockets and Crimp Sockets. Brass Silver Contin. Dimensions Pin Part Thread Current Dia. Number A B C D E (Amp) Dia. Ref. 2 mm M3x mm mm / mm /

6 Threaded Sleeve Socket Assembly and Application Threaded Sleeve Sockets The Threaded Sleeve Socket Assembly is designed for High Current in a restricted space. The Sleeve can be screwed directly into a threaded bus bar or it may be inserted into a drilled hole in the bus bar with tightened nuts on each side of the bus bar. A Crimp Pin or Thread Mount Pin can be attached to a cable for the completed connector. Body Brass Louvertac Band Beryllium Copper Body Silver Louvertac Band See Table Contin. Voltage Dimensions Louvertac Mating Part Thread Current Drop A B C D Band Pin Dia. Number (Amp) (mv) Dia. Plating 2 mm / Silver 4 mm / Gold 6 mm / Gold 8 mm / Silver 12 mm / A UNF Silver 5

7 Crimp Pins Crimp Pins feature a mechanism for locking the pin into a housing designed by the customer. The 2 mm and 4 mm pins are crimped with a Daniels Hand Crimp Tool. Pin sizes from 6 mm to 8 mm may be crimped with the indicated tooling and a DYNA-CRIMP electric-hydraulic power unit. The large variety of sizes have ratings from 24 continuous amps and can be mated with Thread Mount Socket Assemblies, Threaded Sleeve Socket Assemblies or Crimp Sockets. Body Copper Alloy Retention Spring Stainless Steel or Beryllium Copper Body Silver Pin Dia. 2 mm 4 mm 6 mm 8 mm Part No. Contin. Voltage Dimensions Use Tooling Part Numbers Current Drop A B C D E F G with Crimp Crimp Extraction (Amp) (mv) Dia. Dia. Dia. AWG Die Head Tool Notes: 1. Additional information on AMPOWER terminal hydraulic crimping is available in Catalog Application Specification M310 TP M310 TP M310 TP M310 TP /

8 Crimp Sockets Crimp Sockets feature a mechanism for locking the socket into a housing designed by the customer. An AMP extraction tool is offered to remove the contact. The 2 mm and 4 mm sockets are crimped with a Daniels Hand Crimp Tool. Socket sizes from 6 mm to 8 mm may be crimped with the indicated tooling and a DYNA-CRIMP electric-hydraulic power unit. The large variety of sizes have ratings from 24 continuous amps and can be mated with Thread Mount Pins or Crimp Pins. Body Copper Alloy Louvertac Band Beryllium Copper Retention Spring Stainless Steel or Beryllium Copper Body Silver Louvertac Band Silver Mating Contin. Voltage Dimensions Use Tooling Part Numbers Part Pin No. Current Drop B C with Crimp Crimp Extraction Dia. (Amp) (mv) A Dia. Dia. D E F AWG Die Head Tool 2 mm 4 mm 6 mm 8 mm mm * mm * M310 TP M310 TP M310 TP M310 TP / / MCM * Socket contact uses retention ring (not supplied) for locking contact in housing. See Application Specification for details. Notes: 1. Additional information on AMPOWER terminal hydraulic crimping is available in Catalog Application Specification

9 High Current Upgrade Program Metrimate Drawer Connector Contacts, Size 8 The Louvertac bands have the versatility of being designed into contact dimensions used in existing AMP connectors. Metrimate High Current contacts have been designed to fit into the existing Drawer Connector housings. A fully energized 8 position connector with 8 gage wires can handle 30 amps per line with a 30 C T-rise on either the cable-to-cable or cable-to-board. Standard Size 8 Socket Standard Size 8 Pin Cable-to-Cable Contact Body Copper Alloys Louvertac Band Beryllium Copper Retention Spring Stainless Steel Gold Product Specification Metrimate Pin and Socket with Louvertac High Current Contact Connector Voltage Rating 600 VAC High Current Size 8 Socket High Current Size 8 Pin Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A Contacts Wire Size Contact Part Numbers AWG Pin Socket Crimp Tools Daniels Hand Tool #M310 or AMP P/N Positioner #TP944 or AMP P/N Extraction Tool Part No or Cable-to-Board Contact Body Copper Alloys Louvertac Band Beryllium Copper Retention Spring Stainless Steel Gold.12 Diameter Solder Tail Pins Part No A typical application would have solder tail pins mounted into the receptacle and crimp sockets mounted into the plug. Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A Drawer Connector Housings Size Housing Part Numbers Configuration Plug Receptacle 8 Positions (8 Size 8 Cavities) 15 Positions (3 Size 8 Cavities & 12 Size 16 Cavities) Extraction Tool Part No N o t e s : 1. High Current contacts with Louvertac bands are NOT intermateable with any other contact. 2. Additional information on connectors is available in Catalog

10 High Current Upgrade Program Universal MATE-N-LOK II Connectors The Louvertac bands have the versatility of being designed into contact dimensions used in existing AMP connectors. Universal MATE-N-LOK II High Current contacts have been designed to fit into an existing Universal MATE-N-LOK II housing. In a cable-to-cable application, the initial T-Rise test of a fully energized 2 circuit connector with 10 gage wires has shown a 32 amp capability per line with a 30 C T-rise. Cable-to-Cable Body Copper Alloy Louvertac Band Beryllium Copper See Table Latch Disengaging Tool Part No Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A Passed test by VDE under their Registration Number 3915/Continuous Surv e i l l a n c e Design Objective Application Specification Connector Voltage Rating 600 VA C Cable-to-Right-Angle Board When the Louvertac contacts are used in a cable-to-r/a board application, the initial T-Rise test of a fully energized 2 circuit connector with 10 gage wire and a 2 oz. foil board has shown a 32 amp capability per line with a 30 C T-rise. Housing UL 94V-0 Nylon Contact Body Copper Alloy Louvertac Band Beryllium Copper Silver Solder Tail Diameter.052 [1.32] Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A Passed test by VDE under their Registration Number 3915/Continuous Surv e i l l a n c e Design Objective Connector Voltage Rating 600 VA C Contacts Wire Size Contact Part Numbers Louvertac AWG Pin Socket Band Plating Crimp Tools Lubricated Silver No Daniels Silver Hand Tool #M310 or No Gold AMP P/N , No Silver Positioner #TP1013 or Yes AMP P/N Silver Yes High Current Socket Part No Plug Part No Plug Part No Standard MATE-N-LOK II Pin High Current Pin Part No Standard MATE-N-LOK II Socket Connector Housings No. of CircuIts Socket Header Connector Housings No. of Kit Part Numbers CircuIts Plug Cap Right-Angle Socket Header Part No Part Numbers Socket Header with Lubricated Contacts* Cap Part No Mates with Plug Housing *Mates with plug housing shown and with lubricated MATE-N-LOK II high current pin contacts. N o t e s : 1. High Current contacts with Louvertac bands are NOT intermateable with any other contact. 2. Additional information on connectors is available in Catalog

11 High Current Upgrade Program Universal MATE-N-LOK II Connectors ( C o n t i n u e d ) Vertical Pin Headers High Current Universal MATE-N-LOK II Vertical Pin Headers are designed to mate with Universal MATE-N-LOK II Plugs with High Current Socket contacts. All housings are polarized to provide for proper circuit board placement. Eight versions are available from 2 circuits to 15 circuits. In a cable-to-vertical board application, the initial T-rise of a fully energized 2 circuit connector with 10 gage wire and a 2 oz. foil board has shown a 36 amp capability per line with a 30 C T- r i s e. 2 Circuit Part No , * Part No (Lubricated Contacts) 6 Circuit Part No , Part No (.235 [5.97] Tail Length), Part No (Tube Packaged), * Part No (Lubricated Contacts) Housing UL 94V-0 Nylon Contacts Copper Alloy Solder Tail Diameter.052 [1.32] Silver Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR Passed test by VDE under their Registration Number 3915/Continuous Surv e i l l a n c e Design Objective Connector Voltage Rating 600 VA C 3 Circuit Part No , * Part No (Lubricated Contacts) 9 Circuit Part No Circuit Part No , * Part No (Lubricated Contacts) 12 Circuit Part No , Part No (Tube Packaged) 4 Circuit Select Load (See Table) Pin Part No. Location S H 2 H H 3 S S 4 S S S = Standard MATE-N-LOK II Contact H = High Current MATE-N-LOK II C o n t a c t 5 Circuit Part No Circuit Part No N o t e s : 1. High Current contacts with Louvertac bands are NOT intermateable with any other contact. 2. Additional information on connectors is available in Catalog Recommended PC Board Thickness.062 [1.57]. 10 *Mate with MATE-N-LOK II plug housings with lubricated high current socket contacts.

12 High Current Upgrade Program Type XII Contacts The features of the High Current Type XII contact have been designed to fit into the existing AMP Multimate Connectors such as CPC (Circular Plastic Connector), CMC (Circular Metal Connector), G Series, and M Series housings. An initial T-Rise test in free air has shown a 60 amp capability with a 30 C T-Rise with 8 gage wires. The contact may be crimped onto 8 AWG wire with a Daniels Hand Tool M310 or AMP P/N and Positioner TP1068S or AMP P/N Standard Type XII Socket High Current Type XII Socket Part No Standard Type XII Pin High Current Type XII Pin Part No Cable-to-Cable Body Copper Alloy Louvertac Band Beryllium Copper Retention Spring Stainless Steel Body Silver Louvertac Band Gold Current Rating for 30 C Temperature Rise 100% Energized 3 Circuit Connector (Wire-to-Wire) Type XII Ground Pin Part No * * Not recommended for CPC connectors. Extraction Tool Part No Current-Carrying Capacity. The graph shows current-carrying capacity versus temperature rise for a fully energized 3 position CPC plug P/N and receptacle P/N These initial representative amperage ratings were conducted with 8 AWG wires that were 3 feet long. Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Plug (For Sockets) Square Flange Receptacle (For Pins) N o t e s : 1. High Current contacts with Louvertac bands are NOT intermateable with any other contact. 2. Additional information on CPC and CMC connectors is available in Catalog Additional information on G Series connectors is available in Catalog Additional information on M Series connectors is available in Catalog Additional information on LGH connectors is available in Catalog

13 High Current Upgrade Program Size 16, Type II and Type III+ Contacts The features of the High Current Size 16 contact have been designed to fit into the existing AMP Multimate Connectors such as CPC (Circular Plastic Connector), C M C (Circular Metal Connector), G Series, M Series, Econoseal Metrimate Square Grid and Drawer Connector housings. An initial T-Rise test in free air has shown a 23 amp capability with a 30 C T-Rise. The contact may be crimped onto 14 AWG wire with an AMP hand tool P/N Use turret TH502 ( ) for the pin and turret TH501 ( ) for the socket. Standard Type II Socket Standard Type III+ Socket High Current Size 16 Wire Size Socket Part No. AWG Loose Piece Tape Standard Type II Pin Standard Type III+ Pin Pin Body Leaded Brass; Copper Alloy (Board Mount) Socket Body Copper Alloy Louvertac Band Beryllium Copper Retention Spring Stainless Steel Body Silver Louvertac Band Gold High Current Size 16 Pin (Board Mount) Part No High Current Size 16 Wire Size Pin Part No. AWG Loose Piece Tape Pos. CPC Posted Square Flange Receptacle Part No Mates with CPC Plug (Part No ) with either Type II or High Current Socket contact Extraction Tool Part No Current-Carrying Capacity. The graph shows current-carrying capacity versus temperature rise for a fully energized 6 position Metrimate Square Grid plug P/N and receptacle P/N These initial representative amperage ratings were conducted with 14 AWG wires that were 2 feet long. Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Current Rating for 30 C Temperature Rise 100% Energized 6 Circuit Metrimate Connector (Wire-to-Wire) 12 Plug (for Sockets) Receptacle (for Pins) N o t e s : 1. High Current contacts with Louvertac bands are NOT intermateable with any other contact. 2. Additional information on CPC and CMC connectors is available in Catalog Additional information on G Series connectors is available in Catalog Additional information on M Series connectors is available in Catalog Additional information on Metrimate connectors is available in Catalog Additional information on Econoseal connectors is available in Catalog Additional information on LGH connectors is available in Catalog

14 High Current Upgrade Program Size 20 Posted Contacts The High Current Size 20 contact has been designed to fit into the Series 109 AMPLIMITE Connectors per MIL-C Body Copper Alloy Louvertac Band Beryllium Copper Body Gold Louvertac Band Gold High Current Size 20 Socket Standard Size 20 Socket Louvertac Band Standard Size 20 Pin High Current Size 20 Pin Current-Carrying Capacity. The High Current Size 20 contact with a 20 gage wire attached to the.030 diameter solder tail acquired an initial 30 C T-Rise of amps in free air. Pin Part No Socket Part No The contacts can be sold loose piece or installed into any of the MIL Standard connectors. Pin and Socket Insertion/Extraction Tool Part Number or MIL number M81969/1-02 Insertion tip, for replacement Part Number Extraction tip, for replacement Part Number Typical Fully-Loaded 37 Position Plug and Receptacle N o t e s : 1. High Current contacts with Louvertac bands are NOT intermateable with any other contact. 2. Additional information on connectors is available in Catalog

15 AMPOWER Multi Pin Plus Connector The AMPOWER Multi Pin Plus Connector is manufactured from a modular mold that allows the finished housing to be molded into thousands of different contact configurations. Standard modules are offered in 2, 3, 4 and 8 positions with contact amperages ranging from signal to 150 amps. Pin contacts can be installed into the Plug Housing or the Receptacle Housing. Socket contacts can be installed into the Plug Housing or the Receptacle Housing. Any combination of the modules could be selected and molded into a one-piece housing from 1" to 6" long. Custom modules can be designed and molded to fit many other AMP contacts. Dimensions shown below are the approximate width of each module.* The connector can be used in blindmate drawer, wire-to-wire, wire-to-board, and board-to-board applications. End Module 8-Position Multimate Module (Signal/Size 16 Contact) 2-Position 9 mm Contact Module End Module 4-Position 3 mm Contact Module Spacer End Module 3-Position 3 mm AC Contact Module Receptacle 2-Position 9 mm Contact Module Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR Product Specification Position 3 mm Contact Module 8-Position Multimate Module (Signal/Size 16 Contact) Spacer 3-Position 3 mm AC Contact Module End Module *For example: Using both end modules (always required) and a 2-position 9 mm contact module, a 4-position 3 mm contact module, and two (2) 8-position signal/size 16 contact modules would produce a connector approximately [61.0] in length (.492 [12.5] x [20.0] [8.0] [4.0] x 2). Plug 14

16 AMPOWER Multi Pin Plus Connector (Continued) Standard 65-Position Plug and Receptacle Housing Designed to accept 65 contacts from signal level to 150 amps. The housing accepts: 2-9 mm Contacts 12-3 mm Contacts 48 - Signal/Size 16 Contacts 3-3 mm AC Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC Signal/Size 16 9 mm Contacts 3 mm Contacts Contacts 3 mm AC Contacts Signal/Size 16 3 mm AC Contacts Contacts 3 mm Contacts 9 mm Contacts Receptacle (shown) with two 6-32 inserts (Front Mounted) Plug (shown) with two 6-32 inserts (Front Mounted) Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A 15

17 AMPOWER Multi Pin Plus Connector (Continued) Standard 35-Position Plug and Receptacle Housing Designed to accept 35 contacts from signal level to 30 amps. The housing accepts: 8-3 mm Contacts 24 - Signal/Size 16 Contacts 3-3 mm AC Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC Signal/Size 16 Contacts Signal/Size 16 Contacts 3 mm Contacts 3 mm AC Contacts 3 mm AC Contacts 3 mm Contacts Receptacle (shown) with two 6-32 inserts (Front Mounted) Plug (shown) with two 6-32 inserts (Front Mounted) Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A 16

18 AMPOWER Multi Pin Plus Connector (Continued) 39-Position Plug and Receptacle Housing Designed to accept 39 contacts from signal level to 150 amps. The housing accepts: 4-9 mm Contacts 8-3 mm Contacts 24 - Signal/Size 16 Contacts 3-3 mm AC Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC Signal/Size 16 Contacts Signal/Size 16 Contacts 9 mm Contacts 3 mm Contacts 3 mm AC Contacts 3 mm AC Contacts 3 mm Contacts 9 mm Contacts Receptacle (shown) with two 6-32 inserts Plug (shown) with two 6-32 inserts Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A 17

19 AMPOWER Multi Pin Plus Connector (Continued) 43-Position Plug and Receptacle Housing Designed to accept 43 contacts from signal level to 30 amps. The housing accepts: 8-3 mm Contacts 32 - Signal/Size 16 Contacts 3-3 mm AC Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC Signal/Size 16 Contacts Signal/Size 16 Contacts 3 mm Contacts 3 mm AC Contacts 3 mm AC Contacts 3 mm Contacts Receptacle Plug Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A 18

20 AMPOWER Multi Pin Plus Connector (Continued) 35-Position Plug and Receptacle Housing Designed to accept 35 contacts from signal level to 30 amps. The housing accepts: 16-3 mm Contacts 3-3 mm AC Contacts 16 - Signal/Size 16 Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC Receptacle Plug Position Plug and Receptacle Housing Designed to accept 28 contacts from signal level to 30 amps. The housing accepts: 4-3 mm Contacts 24 - Signal/Size 16 Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC 3 mm Contacts Signal/Size 16 Contacts Signal/Size 16 Contacts 3 mm Contacts Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A Receptacle (shown) with two 6-32 inserts (Rear Mounted) Plug (shown) with two 6-32 inserts (Rear Mounted) 19

21 AMPOWER Multi Pin Plus Connector (Continued) 24-Position Plug and Receptacle Housing Designed to accept 24 contacts from signal level to 30 amps. The housing accepts: 8-3 mm Contacts 16 - Signal/Size 16 Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC Receptacle Plug Position Plug and Receptacle Housing Designed to accept 11 contacts from signal level to 30 amps. Circuit positions 9 and 11 of the plug are designed so that the socket contact is recessed 5 mm. The housing accepts: 3-3 mm AC Contacts 8 - Signal/Size 16 Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC 3 mm AC Contacts Signal/Size 16 Contacts 3 mm AC Contacts Signal/Size 16 Contacts Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A Receptacle Plug

22 AMPOWER Multi Pin Plus Connector (Continued) 2-Position Plug and Receptacle Housing Designed to accept two 150 amp contacts. The housing accepts: 2-9 mm Contacts Polyester, UL 94V-0 rating Connector Voltage Rating 250 VAC 9 mm Contacts 9 mm Contacts Receptacle Plug Recognized under the Component Program of Underwriters Laboratories Inc., File No. E28476 Certified by Canadian Standards Association, File No. LR7189A 21

23 AMPOWER Multi Pin Plus Connector (Continued) 9 mm Pin Crimp Contact The 9 mm Pin is designed to fit into the 2-Position Module. The Pin has a retention spring that locks the contact into the housing cavity. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The contact can be crimped with the indicated DYNA-CRIMP electric-hydraulic power unit. Body Copper Alloy Retention Spring Beryllium Copper Body Silver Pin Part No Retention Spring Current Tooling Part Numbers Part Contact Use with Rating No. Crimp Crimp Extraction (Amp) Sequence Level* AWG Die Head Tool Third Mate 1/ *When used with other AMPOWER Multi Pin Plus Contacts. 9 mm Socket Crimp Contact The 9 mm Socket is designed to fit into the 2-Position Module. The Socket has a retention spring that locks the contact into the housing cavity. The Socket has a polymer ring and post that helps prevent any finger contact with bare metal surfaces when installed into the Plug or Receptacle housings. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The contact can be crimped with the indicated DYNA-CRIMP electric-hydraulic power unit. Louvertac Band Post Retention Spring Ring Body Copper Alloy Retention Spring B e ryllium Copper Louvertac Band Beryllium Copper Post and Ring Acetyl Body Silver Socket Part No Current Tooling Part Numbers Part Use with No. Rating AWG Crimp Crimp Extraction (Amp) Die Head Tool / Notes: 1. Additional wire sizes and mating levels available upon request. 2. Additional information on AMPOWER terminal hydraulic crimping is available in Catalog

24 9 mm Thread Mount Pin Contact The 9 mm Pin is designed to fit into the 2-Position Module. The Pin has a retention spring that locks the contact into the housing cavity. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The 1/4-28 threads are provided to mount the contact directly to a bus bar. Body Copper Alloy Retention Spring Beryllium Copper Body Silver Extraction Tool Part No AMPOWER Multi Pin Plus Connector (Continued) Pin Part No Threads Retention Spring 9 mm Thread Mount Socket Contact The 9 mm Socket is designed to fit into the 2-Position Module. The Socket has a retention spring that locks the contact into the housing cavity. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The 1/4-28 threads are provided to mount the contact directly to a bus bar. Retention Spring Threads Retention Spring Body Copper Alloy Retention Spring Beryllium Copper Post and Ring Acetyl Socket Part No Body Silver Extraction Tool Part No

25 AMPOWER Multi Pin Plus Connector (Continued) 3 mm Pin Crimp Contact The 3 mm Pin is designed to fit into the 3- and 4-Position Modules. The pin has a retention spring that locks the contact into the housing cavity. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The contact can be crimped with a Daniels Hand Crimp Tool. Retention Spring Body Copper Alloy Retention Spring Stainless Steel Body Silver Part No. Current Rating (Amp) Contact Use with Dimensions Sequence AWG A B First Mate Second Mate Third Mate Third Mate Third Mate First Mate Tooling Part Numbers Crimp Crimp Tool Extraction Hand Tool Positioner Tool M309 TP mm Socket Crimp Contact The 3 mm Socket is designed to fit into the 3- and 4-Position Modules. The Socket has a retention spring that locks the contact into the housing cavity. The Socket has a polymer ring that helps prevent any finger contact with bare metal surfaces when installed into the Plug or Receptacle housings. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The contact can be crimped with a Daniels Hand Crimp Tool. Ring Retention Spring Body Copper Alloy Retention Spring Stainless Steel Louvertac Band Beryllium Copper Ring Acetyl Body Silver Part Current Use with No. Rating AWG (Amp) Dimension A Tooling Part Numbers Crimp Crimp Tool Extraction Hand Tool Positioner Tool M309 TP Note: Additional wire sizes and mating levels available upon request. 24

26 AMPOWER Multi Pin Plus Connector (Continued) 3 mm Solder Tail Pin and Socket A 3 mm Solder Tail Pin and Socket are designed to fit into the 3- and 4-Position Modules. The contacts have a retention spring that locks the contact in the housing cavity. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. Retention Spring Ring Retention Spring Body Copper Alloy Retention Spring Stainless Steel Body Silver Extraction Tool Part No Pin Part No Socket Part No Type III+ Signal Posted Contacts (Replacement Contacts, See Note Below.) Contact Body and Post Brass Retention Spring Stainless Steel See chart. Pin Socket Single contact, free-air test current; not to be construed as contact rating current. Use only for testing. Size 16 Pin Diameter.062 [1.57] (Test Current, 13 Amperes) Loose Piece Contact Part No. Termination Post Contact Method Configuration 3 Termination High Post 1 Termination High Post Pin Socket Pin Socket.045 x.045 Sel. Gold/Nickel Wrap-Type 1.14 x 1.14 Bright Tin-Lead Gold flash over [ ] nickel on entire contact, with [ ] gold to a distance of.200 [5.08] from mating end. Gold thickness controlled on socket O.D. Posts plated tin-lead over copper. Extraction Tool Part No Insertion Tool Part No Note: These contacts are used as replacement contacts for all posted connectors. 25

27 AMPOWER Multi Pin Plus Connector (Continued) 3 mm Hot Mate Pin and Socket A 3 mm Hot Mate Pin and Socket are designed to fit into the 3- and 4-Position Modules. The contacts have a retention spring that locks the contact in the housing cavity. The contacts are rear installed and removed with the Extraction Tool that is inserted in the mating side. The contact can be crimped with a Daniels Hand Crimp Tool. Two contacts were installed into the 3-Position 3 mm AC Module and subjected to 52 amps at 250 VAC for 250 cycles. Contact UL rating 35 A. Pin Part No Retention Spring Retention Spring Body Copper Alloy Retention Spring Stainless Steel Body Gold Socket Part No Part Contact Use with Dimension No. Type Sequence AWG A Pin Second Mate Socket Tooling Part Numbers Crimp Crimp Tool Extraction Hand Tool Positioner Tool M309 TP M309 TP Multimate Pin and Socket Contacts The Multimate contacts are designed to fit into the 8-Position Module. Ty c o Electronics offers many Type III1 c o n t a c t wire sizes and finishes in order to fulfill most signal requirements. The Type III1 pin contacts are used in the third sequence mating cycle. Type III+ Crimp Contacts Contact Size 16 Pin Diameter.062 [1.57] *Test Current 13 amperes (Single contact, free-air test current; not to be construed as contact rating current. Use only for testing.) Contact : A [ ] gold on the electrical engagement area over [ ] nickel. B [ ] gold on the electrical engagement area over [ ] nickel. C Tin *Note: Total current capacity of each contact in any given connector is dependent on the heat rise resulting from the combination of electrical loads of all contacts in the connector arrangement and the maximum ambient temperature in which the connector will be operating. Body Brass Retention Spring Stainless Steel See Table Wire Size Range Ins. Dia. Contact Strip Form Contact No. Loose Piece Contact No. AWG [mm 2 ] Range Code Pin Socket Pin Socket C A B A B C A B C A B C A B C A B C A B Pin Insertion Tools (For Insulation Dia. of.070 [1.78] or less) (For Insulation Dia. of.090 [2.29] max.) Extraction Tool Part No Socket

28 AMPOWER Multi Pin Plus Connector (Continued) Multimate Pin and Socket Contacts (Continued) High Current Size 16 Contacts The High Current Size 16 contact is a Multimate contact that can be used if higher current levels are required (10-15 amps). They fit into the 8-Position Module. The Pin contact can be used in the third sequence mating cycle. AMP P/N is a Multimate contact that is used in the fourth sequence mating cycle and mates with any Size 16 socket. Pin Socket Contact Part Number Wire Size Pin Socket AWG Loose Piece Tape Loose Piece Tape See page 12 for additional information. Size 16 Pin Tooling Part Numbers Part Contact Use with No. Sequence AWG Crimp Turret Hand Tool Fourth Mate Size 16 Solder Tail Pin AMP P/N is a Multimate contact that is used as a High Current Solder Tail Pin Contact and mates with Socket P/N Part No Extraction Tool Part No See page 12 for additional information. 27

29 Connector Mounting Options AMPOWER Multi Pin Plus Connector (Continued) The Plug and Receptacle Housings have been designed to be rigidly mounted to a surface or to float on a surface. Two screw clearance holes in the housings have been provided to allow either housing to be rigidly mounted in the recommended panel cutout. Two threaded inserts can be installed into these holes upon request. Large slots in the housings have been provided to allow either housing to float within the window of the recommended panel cutout. Shoulder screw length will vary based on panel thickness and housing selection. All hardware is commercially available. The X-Y float principle that utilizes the panel cutout and the housing allows as much as 3/16 [4.76] misalignment between the housings Nut 2 Plc. 3/16 Dia. Shoulder Screw 2 Plc. Float Mount Receptacle 6-32 Screw 2 Plc. #6 Split Lockwasher 2 Plc Nut 2 Plc. #6 Split Lockwasher 2 Plc. Rigid Mount Plug 6-32 Nut 2 Plc Screw 2 Plc. Rigid Mount Receptacle 3/16 Dia. Shoulder Screw 2 Plc Nut 2 Plc. Float Mount Plug 28 Panel cutout dimensions are shown on the customer drawing.

30 AMPOWER Multi Pin Plus Connector (Continued) Contact Sequential Mating Cycle A family of Pins have been designed to have four levels of sequence during the Plug and Receptacle mating cycle. 3 mm Pin 1st Mate 3 mm Socket 3 mm Pin 2nd Mate 3 mm Socket 3 mm Pin 3rd Mate 3 mm Socket Size 16 Pin (See page 27) 3rd Mate Size 16 Socket (See page 27) 9 mm Pin 3rd Mate 9 mm Socket Type III+ Pin 3rd Mate Type III+ Socket Size 16 Pin (See page 27) 4th Mate Type III+ Socket 29

31 Fork Connectors Thread Mount Fork The Thread Mount Fork was developed to mount onto a plate or bus bar designed and fabricated by the customer. The Fork is rated at 84 amps (Upper Tolerance Limit) and accepts a.087 thick blade or circuit board. The anti-rotation pin is in place to help prevent the Fork from rotating while tightening the screw. Fork Zinc AI Alloy Louvertac Bands Copper Alloy Screw Steel Fork Silver Louvertac Bands Silver Screw Zinc Part Number Right-Angle Thread Mount Fork Fork Zinc AI Alloy Louvertac Bands Copper Alloy Spring Pin Stainless Steel Fork Silver Louvertac Bands Silver Part Number

32 Louvertac Strip, Torsional Louver Type The Torsional Louver Type Band was designed as an electrical interface that allows the transfer of high current and a more generous tolerance between mating surfaces. A strip can be sized with scissors in an on-site installation. They are available for use in flat and circular applications. A male band is used on the outside diameter of a pin. The female band is used on the inside diameter of a socket. Beryllium Copper See Tables LAO.092 [2.27] Louver Height Tooth Angle 15 Minimum Diameter 1.75 inches Part No. Application Flat or Female Flat or Female Flat or Male Thickness Suggested Current Limit per inch 150 Silver 250 Silver 150 Silver LAOG Louver Height See Table Tooth Angle 45 Minimum Diameter 1.75 inches Part No. Application Flat or Female Flat or Female Flat or Female Suggested Current Louver Thickness Limit per inch Height Unplated Silver Unplated LAIA.050 [1.27] Louver Height Tooth Angle See Table Minimum Diameter inches Part No. Application Flat or Female Flat or Female Flat or Female Flat or Female Flat or Female Flat or Male Flat or Male Thickness Suggested Current Limit per inch Tooth Angle Silver Silver Silver Gold Silver Silver Silver Notes: 1. Product will be sold by the foot except where length is specified. 2. Suggested current limits are application dependent. 3. Additional sizes are available upon request. 31

33 Louvertac Strip, Bridge Louver Type The Bridge Louver Type Band was designed to transfer high currents in very small spaces. A strip can be sized with scissors in an on-site installation. They are available for use in flat and circular applications. A male band is used on the outside diameter of a pin. The female band is used on the inside diameter of a socket. Beryllium Copper LAIII.034 [.86] Louver Height Minimum Diameter 1 inch Suggested Current Limit Per Inch 150 Amps Thickness.006 [.15] Part No. Application Female Silver Male Silver LAIV.026 [.66] Louver Height Minimum Diameter 3 4 inch Suggested Current Limit Per Inch 150 Amps Thickness See Table Part No. Application Thickness Female Silver Male Silver Male Gold LAV.022 [.56] Louver Height Minimum Diameter 3 4 inch Suggested Current Limit Per Inch 120 Amps Thickness See Table Part No. Application Thickness Female Silver Male Silver Male Gold Male Gold Notes: 1. Product will be sold by the foot except where length is specified. 2. Suggested current limits are application dependent. 3. Additional sizes are available upon request.

34 Preformed Female Louvertac Bands Female Torsional Formed Type LA1A/LA1B.050 [1.27] Louver Height Beryllium Copper See Table Tooth Angle See Table Louvertac Bands can be manufactured as preformed diameters. This will allow the insertion of the band into a socket. The diameter indicated is the mating pin diameter that will be inserted into the socket assembly. Consult Product Engineering for mounting details. Part No. Mating Pin Dia. Thickness Suggested Current Limit (A) Tooth Angle Band Type [7.92].004 [.10] 150 Silver 15 LA1A [7.92].006 [.15] 250 Silver 15 LA1A [9.01].006 [.15] 275 Gold 15 LA1A [9.53].006 [.15] 300 Silver 15 LA1A [10.00].006 [.15] 325 Silver 15 LA1A [11.02].006 [.15] 350 Gold 15 LA1A [11.10].006 [.15] 350 Silver 15 LA1A [11.99].006 [.15] 375 Silver 15 LA1A [11.99].008 [.20] 375 Silver 15 LA1A [12.70].006 [.15] 400 Silver 15 LA1A [14.00].006 [.15] 450 Silver 15 LA1A [15.88].006 [.15] 500 Silver 15 LA1A [15.88].008 [.20] 475 Silver 15 LA1A [17.40].006 [.15] 550 Silver 15 LA1A [19.05].006 [.15] 600 Silver 15 LA1A [19.05].008 [.20] 600 Silver 15 LA1A [22.22].006 [.15] 675 Gold 15 LA1A [22.22].006 [.15] 700 Silver 15 LA1A [25.40].006 [.15] 775 Silver 15 LA1A [31.75].006 [.15] 975 Silver 15 LA1A [25.40].008 [.20] 800 Silver 15 LA1A [30.10].006 [.15] 950 Silver 45 LA1B [20.62].008 [.20] 625 Silver 45 LA1B Notes: 1. Suggested current limits are application dependent. 2. Additional sizes are available upon request. 33

35 Preformed Female Louvertac Bands (Continued) Female Bridge Formed Type LAIII through LAVI Beryllium Copper See Table Part No. Mating Pin Dia. Length Thickness Suggested Current Limit (A) Band Type [3.18].47 [11.9].004 [.10] 40 Nickel LAIII [5.00].47 [11.9].006 [.15] 90 Gold LAIII [6.00].47 [11.9].006 [.15] 100 Gold LAIII [6.00].47 [11.9].008 [.20] 120 Gold LAIII [6.00].47 [11.9].008 [.20] 120 Gold LAIII [6.35].47 [11.9].006 [.15] 110 Silver LAIII [6.35].47 [11.9].006 [.15] 110 Gold LAIII [6.35].47 [11.9].008 [.20] 125 Gold LAIII [7.11].47 [11.9].008 [.20] 165 Silver LAIII [7.11].47 [11.9].008 [.20] 125 Gold LAIII [6.35].47 [11.9].006 [.15] 125 Unplated LAIII [8.00].47 [11.9].008 [.20] 185 Silver LAIII [8.00].47 [11.9].008 [.20] 185 Gold LAIII [10.00].47 [11.9].008 [.20] 250 Silver LAIII [11.10].47 [11.9].008 [.20] 270 Silver LAIII [11.99].47 [11.9].008 [.20] 300 Silver LAIII [12.70].47 [11.9].008 [.20] 300 Tin LAIII [9.53].47 [11.9].008 [.20] 200 Gold LAIII [6.35].47 [11.9].006 [.15] 110 Gold LAIII [0.64].32 [8.13].005 [.13] 15 Gold LAIV [1.57].32 [8.13].006 [.15] 25 Silver LAIV [1.57].32 [8.13].006 [.15] 25 Gold LAIV [2.03].32 [8.13].006 [.15] 35 Gold LAIV [2.36].32 [8.13].005 [.13] 40 Gold LAIV [2.54].32 [8.13].006 [.15] 50 Gold LAIV [3.18].32 [8.13].006 [.15] 60 Gold LAIV [4.00].32 [8.13].006 [.15] 65 Gold LAIV [4.00].32 [8.13].006 [.15] 65 Silver LAIV [4.00].32 [8.13].006 [.15] 65 Gold LAIV [4.00].32 [8.13].008 [.20] 75 Gold LAIV [4.39].32 [8.13].006 [.15] 70 Gold LAIV [5.54].32 [8.13].006 [.15] 95 Silver LAIV [6.45].32 [8.13].006 [.15] 110 Silver LAIV [6.35].32 [8.13].006 [.15] 120 Gold LAIV [7.11].32 [8.13].006 [.15] 130 Gold LAIV [8.00].32 [8.13].006 [.15] 165 Silver LAIV [9.53].32 [8.13].006 [.15] 175 Gold LAIV [9.50].32 [8.13].007 [.18] 175 Tin LAIV [15.30].32 [8.13].006 [.15] 285 Gold LAIV [3.18].32 [8.13].006 [.15] 60 Silver LAIV [4.00].32 [8.13].006 [.15] 65 Silver LAIV [18.40].32 [8.13].006 [.15] 350 Silver LAIV [0.76].20 [5.10].005 [.13] 13 Gold LAV [0.76].20 [5.10].005 [.13] 11 Unplated LAV [1.40].20 [5.10].005 [.13] 20 Gold LAV [1.54].20 [5.10].004 [.10] 22 Gold LAV [1.57].20 [5.10].005 [.13] 25 Gold LAV [1.65].20 [5.10].005 [.13] 23 Unplated LAV [2.03].20 [5.10].004 [.10] 30 Silver LAV [2.03].20 [5.10].005 [.13] 30 Gold LAV Notes: 1. Suggested current limits are application dependent. 2. Additional sizes are available upon request. 34

36 Preformed Female Louvertac Bands (Continued) Female Bridge Formed Type LAIII through LAVI (Continued) Beryllium Copper See Table Part No. Mating Suggested Band Length Pin Dia. Thickness Current Limit (A) Type [2.03].20 [5.10].008 [.20] 30 Gold LAV [2.36].20 [5.10].005 [.13] 35 Gold LAV [3.18].20 [5.10].004 [.10] 45 Gold LAV [3.18].20 [5.10].005 [.13] 45 Silver LAV [3.18].20 [5.10].005 [.13] 45 Gold LAV [3.18].20 [5.10].005 [.13] 45 Unplated LAV [4.40].20 [5.10].006 [.15] 65 Gold LAV [5.70].20 [5.10].006 [.15] 85 Gold LAV [6.35].20 [5.10].006 [.15] 110 Gold LAV [6.30].20 [5.10].006 [.15] 95 Tin LAV [10.2].20 [5.10].005 [.13] 150 Gold LAV [19.0].20 [5.10].005 [.13] 285 Gold LAV [3.40].20 [5.10].006 [.15] 50 Gold LAV [1.00].10 [2.54].004 [.10] 15 Gold LAVI [1.60].10 [2.54].004 [.10] 22 Gold LAVI [3.20].10 [2.54].004 [.10] 45 Gold LAVI [6.50].10 [2.54].004 [.10] 95 Gold LAVI [6.90].10 [2.54].004 [.10] 65 Gold LAVI [6.50].10 [2.54].004 [.10] 95 Unplated LAVI Preformed Male Louvertac Bands Male Torsional Formed Type LA1AS/LA1BS Beryllium Copper See Table Tooth Angle See Table Louvertac Bands can be formed into a male shape for use on a pin. Selection begins with the amperage requirement and then the mating hole diameter. Consult Product Engineering for mounting details. Part No. Mating Hole Dia. Thickness Suggested Current Limit (A) Tooth Angle Band Type [7.92].006 [.15] 200 Silver 15 LA1AS [15.7].006 [.15] 425 Silver 15 LA1AS [19.0].008 [.20] 550 Silver 15 LA1AS [25.4].006 [.15] 750 Silver 15 LA1AS [12.7].006 [.15] 350 Silver 45 LA1BS [19.0].008 [.20] 550 Silver 45 LA1BS [19.8].006 [.15] 575 Silver 45 LA1BS [22.22].008 [.20] 650 Silver 45 LA1BS [30.4].008 [.20] 900 Silver 45 LA1BS [36.8].006 [.15] 1100 Silver 45 LA1BS Notes: 1. Suggested current limits are application dependent. 2. Additional sizes are available upon request. 35

37 Preformed Male Louvertac Bands (Continued) Male Bridge Formed Type LAIIIS through LAVIS Beryllium Copper See Table Part No. Mating Hole Dia. Length Thickness Suggested Current Limit (A) Band Type [4.0].470 [11.9].008 [.20] 75 Gold LAIIIS [6.35].470 [11.9].008 [.20] 130 Silver LAIIIS [6.3].470 [11.9].008 [.20] 130 Silver LAIIIS [7.9].470 [11.9].008 [.20] 175 Unplated LAIIIS [7.9].470 [11.9].008 [.20] 175 Silver LAIIIS [7.9].470 [11.9].008 [.20] 175 Gold LAIIIS [6.0].470 [11.9].008 [.20] 120 Nickel LAIIIS [4.0].470 [11.9].008 [.20] 75 Nickel LAIIIS [2.0].320 [8.13].005 [.12] 30 Nickel LAIVS [4.0].320 [8.13].006 [.15] 65 Unplated LAIVS [3.99].320 [8.13].006 [.15] 60 Gold LAIVS [1.27].320 [8.13].005 [.12] 235 Unplated LAIVS [9.38].320 [8.13].004 [.10] 170 Unplated LAIVS [9.53].320 [8.13].006 [.15] 175 Tin LAIVS [9.53].320 [8.13].006 [.15] 175 Gold LAIVS [6.35].200 [5.10].006 [.15] 95 Gold LAIVS [1.3].100 [2.54].004 [.10] 17 Gold LAVIS [3.23].100 [2.54].004 [.10] 22 Gold LAVIS [3.96].100 [2.54].004 [.10] 65 Gold LAVIS Notes: 1. Suggested current limits are application dependent. 2. Additional sizes are available upon request. 36

38 Part Number Index N o t e : This index lists all cataloged parts by base no. only. Complete part nos. (with prefixes and/or suffixes) are shown on the page(s) indicated. Part No. Page , , 7, , 7, , 7, , , , , , , , , , 34, , , 36 Part No. Page , 27, , 27, , , Part No. Page , , , 12, 25, 26, , 7, , 9, , 25, , , , , , , , 27 37

39 Engineering Notes 38