Anderson Powerpole Connectors: crimper and 30/45 amp?

[Gatorbotics]

Hi everyone!

Team 1700 is looking to try out Anderson Powerpole connectors on our electronics board this year, and we ran into three questions while shopping for options online:

1. To crimp 30 amp Powerpole contacts, do we need to buy the special Powerpole crimpers or can we get by with our quick disconnect crimper (https://goo.gl/photos/EC2VEcYoi4ALJThB9)? (In the long run, we'd definitely invest in the proper crimper, but we'd just like to be able to test out a few for now).
2. Are the 30 amp Powerpoles okay for our drive CIMs, which have 40 amp breakers?
3. If not, can the 45 amp Powerpoles fit 14 gauge wire? On the website, the suggested gauge is 10.

Thank you very much!
Claire

[Chief Hedgehog]

I HIGHLY recommend that you purchase the Anderson PowerPole crimpers. Unless you enjoy loads of frustration, use the correct tool the first time.

[seth.brugler]

I also vouch for a powerpole crimper. Our team uses the TRIcrimp and it has worked great for years.

[Kevin Sevcik]

I HIGHLY recommend that you purchase the Anderson PowerPole crimpers. Unless you enjoy loads of frustration, use the correct tool the first time.Ditto this. Crimping with anything else is likely to end with wires that pull out far too easily, and a contact that can't be properly inserted into the connector.

That said, if that's a replaceable jaw crimper, you might be able to find some roughly compatible jaws. But that'll likely run you nearly as much as the actual crimpers (http://www.powerwerx.com/crimping-tools/tricrimp-crimping-powerpole-contacts.html).

For the 30/45 amp question, you should mostly match the contact to the wire gauge. Too small wire in a crimped connection makes for a loose connection. I'd stick with the wire gauge recommendations instead of the amperage.

EDIT: Looking at the tech data sheet (http://www.powerwerx.com/techdata/PP45.pdf) for the PP45, it actually can go down to 14 gauge. I'd be a bit careful about the crimp at that point, however. Probably want to set the crimper a bit hard for those crimps.

[GeeTwo]

Before we got a proper APP crimper, we had one student and two mentors who could crimp APPs with 90% or better consistency, and most other students at 50% or less. Now most of the controls students and several others can reliably make APP crimps. Get the tool.

Edit: We crimp, tug test, then flow a tiny bit of solder to the inside of the connection; we heat the stranded wire on one side and feed it into the wire on the opposite side. Don't flow any solder onto the outside of the APP connector, or it will not fit into the housing.

[Knufire]

For the 30/45 amp question, you should mostly match the contact to the wire gauge. Too small wire in a crimped connection makes for a loose connection. I'd stick with the wire gauge recommendations instead of the amperage.

Second this. Use the PP45 crimp for 10 gage wire, and the PP30 for 12-14 gage.

[Gatorbotics]

Thanks for all the replies! Sounds like we should invest in the proper crimping tool.

To the 30/45 question, we know we should be using the 30 amp connectors for our 12-14 gauge wire. But will they pass inspection because of Rule R50 saying the electronics need to be rated to carry at least as much as the breaker?

[Kevin Sevcik]

Thanks for all the replies! Sounds like we should invest in the proper crimping tool.

To the 30/45 question, we know we should be using the 30 amp connectors for our 12-14 gauge wire. But will they pass inspection because of Rule R50 saying the electronics need to be rated to carry at least as much as the breaker?A good point. And upon further research, the detailed data sheet (http://www.powerwerx.com/techdata/PP45.pdf) on the PP45 says that it can go down to #14 gauge. It's just the website that suggests differently. I'm edited my previous posts with this in mind.

Mind you, the data sheet also says it can only handle 40 amps for 2 seconds at 14 gauge, but whatever. I think standard quick disconnects are even worse rated, in fact.

[pilleya]

The Talon SRX and Victor SP motor controllers use "wet noodle wire", this is 12GA but in most cases a 45 amp Powerpole connector is required to crimp it because of the nature of the strands and the size.

I strongly recommend the use of powerpoles, it certainly makes everything a lot easier.

I really like the Tri-crimp tool, it definitely makes crimping the Powerpoles easy
http://www.andymark.com/product-p/am-2554.htm

[Sperkowsky]

The Talon SRX and Victor SP motor controllers use "wet noodle wire", this is 12GA but in most cases a 45 amp Powerpole connector is required to crimp it because of the nature of the strands and the size.

I strongly recommend the use of powerpoles, it certainly makes everything a lot easier.

I really like the Tri-crimp tool, it definitely makes crimping the Powerpoles easy
http://www.andymark.com/product-p/am-2554.htm
Second this those cables are hair to crimp with the normal size

Powerwerx has the best assortment

[pilleya]

I've found a company called acer racing, to be reasonably good value+"free"(nothing is free) shipping even internationally which is great for international teams. They don't have an assortment of different colours or anything, but probably not necessary.

http://www.acerracing.com/Powerpole_Connectors-80-1.html

[Al Skierkiewicz]

Power Poles are available from a lot of sources but using anything other than intended crimpers will make them ineffective. You can obtain a great crimper from West Mountain Radio http://www.westmountainradio.com/ (the supplier for the CBA-IV battery charge tester) and an inexpensive crimper that will do all PowerPoles up to the 50 amp used in the SB50 from high Sierra http://www.hamcq.com/ for $35