I suspect that part of the problem seen by a few PowerPole users is that the wrong tool was used to crimp the terminals. The correct tool should be intended for non-insulated terminals, which rules out those made for insulated lugs, as well as Vise-Grips and Channel-Lock pliers. Both Thomas & Betts and Gardner-Bender make the correct tools. I personally like the T&B WT111M Crimping Tool, shown on page J92 of the Thomas & Betts catalog here:
<www-public.tnb.com/contractor/docs/catamount.pdf> The PowerPole terminal lug must be crimped with a tool that indents the body of the terminal without altering the outside diameter or shape. I have seen a lot of these terminals so badly deformed that they could not be fully inserted into the PowerPole insulator shell; it's not surprising that poor contact results. I'd like to pass along a tip: The next time you buy a bag of PowerPole connectors, take the time to cement the red and black insulators into pairs, using a slow-setting cyanoacrylate glue. Loctite "Goof Proof" Super Glue is a good choice, since it stays liquid long enough to get the two halves of the connector aligned. When I have connector bodies prepared in advance, it takes just seconds to make up a new power cord using #10 AWG red/black primary wire from a spool. I have been using the 30-ampere Anderson PowerPole connectors for many years, and have never had any problems with them. 73, Eric Lemmon WB6FLY -----Original Message----- From: [email protected] [mailto:[EMAIL PROTECTED] On Behalf Of Fred Flowers Sent: Saturday, March 24, 2007 8:42 AM To: [email protected] Subject: RE: [Repeater-Builder] Re: Power-Pole connectors NOT for power What is the problem? The directions say, "Push in until they click". How hard is that? The little ones go together just like the big ones. Anybody with one eye and half sense can do it. They are the greatest thing to come along since caned beer. I use West Mountain rig runners in my truck, in the shack, & in my travel trailer. I've never had any problem. Fred N4GER -----Original Message----- From: [email protected] <mailto:Repeater-Builder%40yahoogroups.com> [mailto:[email protected] <mailto:Repeater-Builder%40yahoogroups.com> ] On Behalf Of Paul Metzger Sent: Saturday, March 24, 2007 10:31 AM To: [email protected] <mailto:Repeater-Builder%40yahoogroups.com> Subject: Re: [Repeater-Builder] Re: Power-Pole connectors NOT for power I second that. I myself have found these little power pole connectors (which are recommended by emergency groups) to be a bit too delicate for me. And if improperly built, will have little or almost no contact tension at all. Honestly I was a little shocked when I started seeing these little buggers marketed for emergency amateur radio purposes. The bright side I see in that is everyone can connect with minimal fuss. But if the connectors were improperly built, I wouldn't be surprised to see a few of these tapped up during a real disaster in order to keep them from falling out of their other mating half. For years, I myself have utilized the larger SB 50A Anderson connectors on my primary Amateur Radio (TS-450 / IC-910) and Solar system at my home QTH. Now try and pull those babies apart. Talk about contact tension. You can't accidently tug on you power harness and pull these apart. One more thing, my jaw dropped when I had built my K2-100W. It uses a chassis mount variant of the tiny power pole connectors out from the rear of the unit. Well, just my two cents. Paul Metzger K6EH
