[Elecraft] Power Pole connectors

[Jim Brown]

On Tue,2/17/2015 10:41 AM, Chris Hallinan wrote:
> I do recall that
> they were difficult to insert into the plastic shell after soldering
> because some solder leaked out around the contacts, and I had to
> basically clean it off.

I've assembled hundreds of Power Pole connector sets -- they're on 
everything in my station that runs on DC, and on all of the non-ham gear 
powered by wall warts or other DC supplies. I've never seen a Power Pole 
crimper -- all of mine are soldered.

I find them very easy to do, once you understand how they work. Inside 
each plastic housing is a spring. The contacts have a sort of curled lip 
that is intended to fit over that spring, which locks it in position. 
The contact must be inserted so that the curl is in the right direction, 
and it must be pushed all the way to the spring. Usually you will hear a 
click when that happens.

For small diameter wire, I often must use a small screw driver (like the 
miniature Xcelite Red or Green) to push the contact from the wire side 
of the housing. For large diameter wire, it may be necessary to strip a 
bit more insulation so that it fits into the housing.

The only times I find it difficult to install a Power Pole is when I'm 
using #10 wire, which requires the largest of the three sizes of 
contacts (the type with the U-shaped holder for the wire). The wire must 
be very carefully tinned, inserted very carefully, and the U-shaped 
holder carefully folded over so that it fits into the housing. I do this 
with a pair of needlenose pliers. A crimper might make that easier.

The only times I've had Power Poles disconnect were when the DC cable 
for one of my K3s was too short, and I pulled the radio forward.

73, Jim K9YC