SARC Emergency Communications Committee--Information on Anderson Powerpole® Connectors

	Schaumburg Amateur Radio Club Emegency Communications Committee--Information on Anderson Powerpole® Connectors
A.	Assembly Instructions
A1.	Here is a one-page assembly guide for the 30-Amp series of Anderson Powerpole® connectors. The page includes text and diagrams explaining the mechanical insertion of the contact into the connector body and the assembly of two connector bodies to form a pair. The wire must be crimped, soldered, or both, to the cylindrical barrel of the contact. See A2 below for an inexpensive crimping tool. Note that the cylindrical barrel has a nearly invisible open seam which has implications for both crimping and soldering. When crimping, the point or knife edge of the crimping tool should be applied to the side of the barrel opposite the seam. When soldering, solder can wick along the seam; care should be taken to avoid allowing solder to flow onto the working portion of the contact.
A2.	This page from Patrick Lambert WØIPL shows the construction and installation of the connector. This page mentions a suiltable crimping tool: "When you finish crimping the spade lug to the wire, insure you re-form the crimped portion to round. This will allow easy insertion into the plastic connector body. The easiest crimp tool to get is the Gardner Bender GS-88 available at Home Depot* for about $8 plus tax." [* Editor's note: In the Chicago area, I have found these tools at Menards but not at Home Depot. --nro] Bill Zapel N9WPD has indicated he has a crimping tool which he may make available, but for those who want one of their own, $8 seems pretty reasonable. Here's a link to some more information on the Gardner Bender GS-88 Crimping Tool.
A3.	Here is the Powerpole® Modular Connector Assembly Sheet [PDF} from the manufacturer of the connector, Anderson Power Products.
A4.	This web page from vendor Powerwerx has instructions on on assembly of the connector.
A5.	This web page from vendor Wes Allen d/b/a DCPower, of Beaverton, OR, shows details of the product, including assembly.
A6.	Vendor West Mountain Radio has Detailed Instructions on crimping the contacts onto wires and assembling the connectors.
B.	Examples of RACES, ARES, EMA, and similar organizations that have adopted the Anderson Powerpole® connector for Amateur Radio applications.
B1.	This document [PDF] contains an extensive (180 or so pages) manual on emergency communications [PDF]. It might be a draft of the ARRL Emergency Communications Course. See page 77 for a discussion of the newly recommended Anderson Powerpole® connector and its advantages over the formerly recommended Molex connector.
B2.	This issue of a Newsletter [PDF] of the Wisconsin ARES/RACES organization gives a nice introduction to the Anderson Powerpole® connectors and explains some of their advantages.
	The following are several links to other RACES, ARES, and EMA organizations that have adopted the connector. I gave up collecting links of this type after a dozen or so, because many of them are quite similar, but I believe there are many more organizations than are represented here.
B3.	Bethel (CT) OEM
B4.	Erie County (NY) ARES/RACES
B5.	Carson Valley (NV) Radio Club
B6.	Candlewood (CT) Amateur Radio Association (see "Power Connector Standards")
B7.	Eastern Massechusetts ARES
B8.	Orange County (CA) Radio Amateur Civil Emergency Service
B9.	Loudon County (TN) ARES
B10.	Northern Nevada Amateur Radio Services (ARES, RACES, SKYWARN)
B11.	Chester County (PA) ARES-RACES
B12.	Anaheim (CA) Police Radio Club W6APD
B13.	State of California Office of Emergency Services ACS/RACES
B14.	City of Anaheim, California Office of Emergency Service/Community Emergency Response Team/RACES
B15.	Greene County (OH) ARES (see "GCARES Connector Standard")
C.	Vendors
C1.	This web site from vendor Powerwerx shows the product, with discount pricing at various quantities. Here is information on assembly of the connector. Powerwerx also carries adapters for legacy power connections, and splitters which let you connect multiple devices, without assembling the cables yourself. Powerwerx also carries power supply wire (zip cord). Prices: $69.95 100 pairs connectors, including contacts, housings, and roll pins; $9.50 shipping; $79.45 Total Other items: $0.76/.66/.56 /foot 10-gauge zip-cord (25/50/100 ft quantities) $0.44/.40/.36 /foot 12-gauge zip-cord (25/50/100 ft quantities)
C2.	Vendor Wes Allen d/b/a DCPower of Beaverton, OR. This web page shows details of the product, including assembly. Prices: $9 Bag of 10 pairs of connectors, with contacts but no roll pins; $1/bag discount for 10 bags (100 pairs) purchased at one time.
C3.	Vendor West Mountain Radio (the people who make the RigBlaster brand radio-to-sound-card interface, and the RigRunner brand power distribution panel, which uses the connectors). Detailed Instructions on crimping the contacts onto wires, and assembling the connectors, are available here. Prices: $69.95 100 pairs connectors, incl contacts, housing, but no roll pins; $7.11 Shipping; $77.06 Total Other items: $0.39/.35 10-gauge "64-strand" zip-cord (under 100 ft/over 100 ft) $0.29/.25 12-gauge "64-strand" zip-cord (under 100 ft/over 100 ft)
C4.	Vendor MCM Electronics, Part No. 21-3300: Prices: $10.25 10 pairs of connectors, including contacts, housings, no roll pins $5-7 shipping (MCM charges a $3 handling fee plus the carrier's published rate; $5 surcharge for orders under $25)
C5.	Vendor D & L Antenna Supply Co. Prices: $2 1 (one) pair of connectors, with contacts but no roll pins; $2 shipping
C6.	WARNING: SEVERAL CLUB MEMBERS HAVE REPORTED THAT THIS VENDOR HAS BEEN UNCOOPERATIVE. Vendor Cable Xperts Prices: $8.95 10 pairs connectors, including contacts, housings, no roll pins $39.50 50 pairs connectors, including contacts, housings, no roll pins $69.50 100 pairs connectors, including contacts, housings, no roll pins Other items: $0.31/.28/.26 /foot 10-gauge zip-cord (50/100/250 ft quantities) $0.21/.19/.17 /foot 12-gauge zip-cord (50/100/250 ft quantities)

Page version: 2003-05-25 11:47:05 nro