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Power pole connection comes loose

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Ron Midwin-3

Power pole connection comes loose

I was working cw with about 95 watts when my K3 shut down. I checked the
power pole connection and it had come slightly loose and was pretty warm,
so I let it cool and then re inserted it to the radio, and this seems to
work OK. I've seen some comments about how to make this a more positive
connection. I don't see the roll pin hole on the radio connector?

any suggestions?

Ron
AE6RH

--
Ron Midwin
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Nr4c

Re: Power pole connection comes loose

In normal operation a K3 will not get a properly assembled and
connected PowerPole "pretty warm".

I have gotten them warm, but in circuits pullng 50-70 Amps on some
serious electric motors in high performance electric model sailplanes.

The most common error in assembling Anderson PowerPoles is not
completely seating the silver plated contact in the plastic housing.
When you insert the contact with wire attached, you should hear two
distinct 'clicks' as the curved end of the contact slides over the end
of the spring. When you look into the end of the plastic housing, you
should see the curved tip of the housing covering the spring. I don't
have a K3 manual handy, so I can't verify that there is a cut-away
picture of a properly assembled contact, but there are many such images
on the web, just "Google" "Anderson PowerPole" and the Anderson site
shows the assembly very well.

To remove the contact, you must lift the curved tip over the spring
while pulling back on the wire.

When PowerPoles are correctly assembled, they make a wiping contact
when mating with another PowerPole, this wiping action actually cleans
the surface and the spring insures proper contact pressure. Proper
assembly and mating of the connectors will result in very low
resistance, and no significant temperature rise during service with an
K3.

The roll pin is used to retain alignment of the Red and Black plastic
housings for one cable. there is no 'roll' pin hole to insure proper
mating of the connectors. I have seen a device that looks like a
'chain' locking link than can be used to hold a connector set together,
but I think the hole in the K3 connector is obscured by the case panels.

...bill nr4c

On Mon, 3 Dec 2012 06:14:01 -0800, Ron Midwin wrote:

> I was working cw with about 95 watts when my K3 shut down. I checked
> the
> power pole connection and it had come slightly loose and was pretty
> warm,
> so I let it cool and then re inserted it to the radio, and this seems
> to
> work OK. I've seen some comments about how to make this a more
> positive
> connection. I don't see the roll pin hole on the radio connector?
>
> any suggestions?
>
> Ron
> AE6RH

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Don Wilhelm-4

Re: Power pole connection comes loose

In reply to this post by Ron Midwin-3

Ron,

If it is both getting warm and not holding together firmly, then one or
both connectors are not assembled correctly.

Check by looking into the open end of both connectors. The tip of the
silver plated contact should be fully seated over the spring clip in the
housing. If you can see both the end of the contact tab and the end of
the spring clip, you need to apply additional pressure at the back end
of the connector to seat the contact tab.

73,
Don W3FPR

On 12/3/2012 9:14 AM, Ron Midwin wrote:
> I was working cw with about 95 watts when my K3 shut down. I checked the
> power pole connection and it had come slightly loose and was pretty warm,
> so I let it cool and then re inserted it to the radio, and this seems to
> work OK. I've seen some comments about how to make this a more positive
> connection. I don't see the roll pin hole on the radio connector?
>
>

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Greg Troxel

Re: Power pole connection comes loose

In reply to this post by Ron Midwin-3

I was working cw with about 95 watts when my K3 shut down. I checked the
power pole connection and it had come slightly loose and was pretty warm,
so I let it cool and then re inserted it to the radio, and this seems to
work OK. I've seen some comments about how to make this a more positive
connection. I don't see the roll pin hole on the radio connector?

The other powerpole issue is using a cheap crimp tool, where the pin can
be bent. While I concur 100% with Don's advice about the pins clicking
over the lower pieces, even with them in place they can make bad contact
if they are bent.
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Don Wilhelm-4

Re: Power pole connection comes loose

Greg and all,

OK, I made assumptions - if you do not have the proper crimping tool for
APP connectors, do not use a substitute (there are several suggestions
for substitutes on the web) - solder the connectors. When soldering, be
careful not to get solder on the flat blade of the connector, and do be
aware that the solder may creep up onto the wire.

If the wire is subject to vibration (mobile or aircraft), do NOT solder
because with vibration, the wire flexing will cause an eventual break
right where the end of where the solder has wicked. This is not usually
a problem with home station installations.

If you must solder the connections in a vibration prone situation, plan
to secure the wire to the same object as where the connector plugs about
2 inches away from the connector - that will substantially reduce the
chance for flexing at the point where the solder wicking has ended.

If you have a vibration prone situation, crimping is the only approved
method, get the proper tool and learn how to use it - a poor crimp is
worse than a soldered terminal.

73,
Don W3FPR

On 12/3/2012 9:40 PM, Greg Troxel wrote:

Bob K6UJ

Re: Power pole connection comes loose

In reply to this post by Greg Troxel

After a number of problems of the PowerPole connectors using the cheaper crimper tool
I bought the good crimping tool for the connectors. No more problems.
Yes they have to remain straight. They are fairly easy to bend so be careful. I lay a straight edge
along the backside of the contactor to check for straight. And the second big thing is you need to hear the "click"
as the pins snap in place. Occasionally I dont hear the cick and insert a small narrow blade
screwdriver alongside the wire and push down until I hear the click. As a final check, look
at the end of the connector when finished. You can see if the curved end of the metal contactor
has snapped over the contactor in the power pole. These two things, making sure you dont bend the
contactor and checking for the "click" are the secret to good connections all the time with the PowerPoles.

Another discussion is about whether to push in the roll pin to lock the PP connectors side by side.
My preference is not to use the roll pins. I have had the roll pins drop out. That is the last thing I want is
for one of them to fall down inside a radio. Unfortunately they dont always stay in snugly like they should.
Your call.

73,
Bob
K6UJ

On Dec 3, 2012, at 6:40 PM, Greg Troxel wrote:

> I was working cw with about 95 watts when my K3 shut down. I checked the
> power pole connection and it had come slightly loose and was pretty warm,
> so I let it cool and then re inserted it to the radio, and this seems to
> work OK. I've seen some comments about how to make this a more positive
> connection. I don't see the roll pin hole on the radio connector?
>
> The other powerpole issue is using a cheap crimp tool, where the pin can
> be bent. While I concur 100% with Don's advice about the pins clicking
> over the lower pieces, even with them in place they can make bad contact
> if they are bent.
> ______________________________________________________________
> Elecraft mailing list
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>
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Pierfrancesco Caci

Re: Power pole connection comes loose

Bob K6UJ <[hidden email]> wrote:

>After a number of problems of the PowerPole connectors using the
>cheaper crimper tool
>I bought the good crimping tool for the connectors. No more problems.

Which of the various tools advertized on our magazines is considered "the good crimping tool"?

Thanks

Pf

--
Pierfrancesco Caci

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Bob K6UJ

Re: Power pole connection comes loose

here is the crimping tool (the good one)

http://www.powerwerx.com/crimping-tools/tricrimp-crimping-powerpole-contacts.html

73,
Bob
K6UJ

On Dec 3, 2012, at 10:15 PM, Pierfrancesco Caci wrote:

> Bob K6UJ <[hidden email]> wrote:
>
>> After a number of problems of the PowerPole connectors using the
>> cheaper crimper tool
>> I bought the good crimping tool for the connectors. No more problems.
>
> Which of the various tools advertized on our magazines is considered "the good crimping tool"?
>
> Thanks
>
> Pf
>
> --
> Pierfrancesco Caci
>

ke9uw

Re: Power pole connection comes loose

That's my favorite one. I got it from West Mountain Radio. I also bought one from High Sierra Communications with has a 75 amp position too, but the one from Powerwerx or West Mountain Radio works better for me. If I do a 75 amp crimp, I use the High Sierra one.

Sent from my iPad
Chuck, KE9UW
(Jack for BMW motorcycles)

On Dec 4, 2012, at 12:24 AM, "Bob K6UJ" <[hidden email]> wrote:

> here is the crimping tool (the good one)
>
> http://www.powerwerx.com/crimping-tools/tricrimp-crimping-powerpole-contacts.html
>
>
> 73,
> Bob
> K6UJ
>
>
>
>
>
>
>
> On Dec 3, 2012, at 10:15 PM, Pierfrancesco Caci wrote:
>
>> Bob K6UJ <[hidden email]> wrote:
>>
>>> After a number of problems of the PowerPole connectors using the
>>> cheaper crimper tool
>>> I bought the good crimping tool for the connectors. No more problems.
>>
>> Which of the various tools advertized on our magazines is considered "the good crimping tool"?
>>
>> Thanks
>>
>> Pf
>>
>> --
>> Pierfrancesco Caci
>>
>
> ______________________________________________________________
> Elecraft mailing list
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Chuck, KE9UW

N0AZZ

Re: Power pole connection comes loose

In reply to this post by Pierfrancesco Caci

The West Mountain or any of the ones selling for around $40 are the good
ones.

Fred/N0AZZ

-----Original Message-----
From: [hidden email]
[mailto:[hidden email]] On Behalf Of Pierfrancesco Caci
Sent: Tuesday, December 04, 2012 12:16 AM
To: Bob K6UJ; Elecraft Reflector
Subject: Re: [Elecraft] Power pole connection comes loose

Bob K6UJ <[hidden email]> wrote:

>After a number of problems of the PowerPole connectors using the
>cheaper crimper tool I bought the good crimping tool for the
>connectors. No more problems.

Which of the various tools advertized on our magazines is considered "the
good crimping tool"?

Thanks

Pf

--
Pierfrancesco Caci

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Phil Salas

Re: Power pole connection comes loose

In reply to this post by Bob K6UJ

“... Another discussion is about whether to push in the roll pin to lock the
PP connectors side by side.My preference is not to use the roll pins. ...”

I stopped using roll-pins a long time ago. I put a drop of superglue on the
black/red connectors and then slide them together.

Phil – AD5X

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George

Re: Power pole connection comes loose

In reply to this post by Ron Midwin-3

I cut a piece of Q Tip stem and use it. Non conductive. I do use super glue
also. Never had any trouble with these connectors. 73 George/W2BPI
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Terry Schieler-2

Re: Power pole connection comes loose

In reply to this post by Bob K6UJ

I don't use the metal PP roll pins for the same reason. I do, however, use plastic cocktail toothpicks with satisfactory results. Wooden toothpicks work as well, as long as it's a snug fit.

Terry, W0FM

-----Original Message-----
From: Bob K6UJ [mailto:[hidden email]]
Sent: Monday, December 03, 2012 9:01 PM
To: Elecraft Reflector
Subject: Re: [Elecraft] Power pole connection comes loose

After a number of problems of the PowerPole connectors using the cheaper crimper tool I bought the good crimping tool for the connectors. No more problems.
Yes they have to remain straight. They are fairly easy to bend so be careful. I lay a straight edge along the backside of the contactor to check for straight. And the second big thing is you need to hear the "click"
as the pins snap in place. Occasionally I dont hear the cick and insert a small narrow blade screwdriver alongside the wire and push down until I hear the click. As a final check, look at the end of the connector when finished. You can see if the curved end of the metal contactor has snapped over the contactor in the power pole. These two things, making sure you dont bend the contactor and checking for the "click" are the secret to good connections all the time with the PowerPoles.

Another discussion is about whether to push in the roll pin to lock the PP connectors side by side.
My preference is not to use the roll pins. I have had the roll pins drop out. That is the last thing I want is for one of them to fall down inside a radio. Unfortunately they dont always stay in snugly like they should.
Your call.

73,
Bob
K6UJ

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N0AZZ

Re: Power pole connection comes loose

Well another thing learned today a use for toothpicks thanks Terry.

Fred/N0AZZ

-----Original Message-----
From: [hidden email]
[mailto:[hidden email]] On Behalf Of Terry Schieler
Sent: Tuesday, December 04, 2012 11:32 AM
To: 'Bob K6UJ'; 'Elecraft Reflector'
Subject: Re: [Elecraft] Power pole connection comes loose

I don't use the metal PP roll pins for the same reason. I do, however, use
plastic cocktail toothpicks with satisfactory results. Wooden toothpicks
work as well, as long as it's a snug fit.

Terry, W0FM

-----Original Message-----
From: Bob K6UJ [mailto:[hidden email]]
Sent: Monday, December 03, 2012 9:01 PM
To: Elecraft Reflector
Subject: Re: [Elecraft] Power pole connection comes loose

After a number of problems of the PowerPole connectors using the cheaper
crimper tool I bought the good crimping tool for the connectors. No more
problems.
Yes they have to remain straight. They are fairly easy to bend so be
careful. I lay a straight edge along the backside of the contactor to check
for straight. And the second big thing is you need to hear the "click"
as the pins snap in place. Occasionally I dont hear the cick and insert a
small narrow blade screwdriver alongside the wire and push down until I hear
the click. As a final check, look at the end of the connector when
finished. You can see if the curved end of the metal contactor has snapped
over the contactor in the power pole. These two things, making sure you
dont bend the contactor and checking for the "click" are the secret to good
connections all the time with the PowerPoles.

Another discussion is about whether to push in the roll pin to lock the PP
connectors side by side.
My preference is not to use the roll pins. I have had the roll pins drop
out. That is the last thing I want is for one of them to fall down inside a
radio. Unfortunately they dont always stay in snugly like they should.
Your call.

73,
Bob
K6UJ

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Millerhill

Re: Power pole connection comes loose

In reply to this post by Terry Schieler-2

A small drop of cyano (crazy) glue is my choice for keeping them together. Of course once you do that, they will never be taken apart or move again. I make up sets ahead of time.

Steve, W1SFR

On Dec 4, 2012, at 12:31 PM, Terry Schieler wrote:

> I don't use the metal PP roll pins for the same reason. I do, however, use plastic cocktail toothpicks with satisfactory results. Wooden toothpicks work as well, as long as it's a snug fit.
>
> Terry, W0FM
>
>
>
> -----Original Message-----
> From: Bob K6UJ [mailto:[hidden email]]
> Sent: Monday, December 03, 2012 9:01 PM
> To: Elecraft Reflector
> Subject: Re: [Elecraft] Power pole connection comes loose
>
> After a number of problems of the PowerPole connectors using the cheaper crimper tool I bought the good crimping tool for the connectors. No more problems.
> Yes they have to remain straight. They are fairly easy to bend so be careful. I lay a straight edge along the backside of the contactor to check for straight. And the second big thing is you need to hear the "click"
> as the pins snap in place. Occasionally I dont hear the cick and insert a small narrow blade screwdriver alongside the wire and push down until I hear the click. As a final check, look at the end of the connector when finished. You can see if the curved end of the metal contactor has snapped over the contactor in the power pole. These two things, making sure you dont bend the contactor and checking for the "click" are the secret to good connections all the time with the PowerPoles.
>
> Another discussion is about whether to push in the roll pin to lock the PP connectors side by side.
> My preference is not to use the roll pins. I have had the roll pins drop out. That is the last thing I want is for one of them to fall down inside a radio. Unfortunately they dont always stay in snugly like they should.
> Your call.
>
>
> 73,
> Bob
> K6UJ
>
>
>
>
>
> ______________________________________________________________
> Elecraft mailing list
> Home: http://mailman.qth.net/mailman/listinfo/elecraft
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> Post: mailto:[hidden email]
>
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Terry Schieler-2

Re: Power pole connection comes loose

Steve,

As I mentioned to Bob, I prefer the plastic cocktail toothpicks over CA or wooden toothpicks. But my reasoning is non-technical.

I have to eat an olive off of the toothpick first. And, of course, that olive has been in a Martini glass which was filled with... ;o)

Terry, W0FM

-----Original Message-----
From: Stephen Roberts [mailto:[hidden email]]
Sent: Tuesday, December 04, 2012 12:37 PM
To: Terry Schieler
Cc: 'Bob K6UJ'; 'Elecraft Reflector'
Subject: Re: [Elecraft] Power pole connection comes loose

A small drop of cyano (crazy) glue is my choice for keeping them together. Of course once you do that, they will never be taken apart or move again. I make up sets ahead of time.

Steve, W1SFR

On Dec 4, 2012, at 12:31 PM, Terry Schieler wrote:

> I don't use the metal PP roll pins for the same reason. I do, however, use plastic cocktail toothpicks with satisfactory results. Wooden toothpicks work as well, as long as it's a snug fit.
>
> Terry, W0FM
>
>
>
> -----Original Message-----
> From: Bob K6UJ [mailto:[hidden email]]
> Sent: Monday, December 03, 2012 9:01 PM
> To: Elecraft Reflector
> Subject: Re: [Elecraft] Power pole connection comes loose
>
> After a number of problems of the PowerPole connectors using the cheaper crimper tool I bought the good crimping tool for the connectors. No more problems.
> Yes they have to remain straight. They are fairly easy to bend so be careful. I lay a straight edge along the backside of the contactor to check for straight. And the second big thing is you need to hear the "click"
> as the pins snap in place. Occasionally I dont hear the cick and insert a small narrow blade screwdriver alongside the wire and push down until I hear the click. As a final check, look at the end of the connector when finished. You can see if the curved end of the metal contactor has snapped over the contactor in the power pole. These two things, making sure you dont bend the contactor and checking for the "click" are the secret to good connections all the time with the PowerPoles.
>
> Another discussion is about whether to push in the roll pin to lock the PP connectors side by side.
> My preference is not to use the roll pins. I have had the roll pins drop out. That is the last thing I want is for one of them to fall down inside a radio. Unfortunately they dont always stay in snugly like they should.
> Your call.
>
>
> 73,
> Bob
> K6UJ
>
>
>
>
>
> ______________________________________________________________
> Elecraft mailing list
> Home: http://mailman.qth.net/mailman/listinfo/elecraft
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> Post: mailto:[hidden email]
>
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> list: http://www.qsl.net/donate.html

Phil Kane-2

Re: Power pole connection comes loose

In reply to this post by Ron Midwin-3

On 12/4/2012 4:59 AM, Phil & Debbie Salas wrote:

> ... Another discussion is about whether to push in the roll pin to lock the
> PP connectors side by side.My preference is not to use the roll pins. ...
>
> I stopped using roll-pins a long time ago. I put a drop of superglue on the
> black/red connectors and then slide them together.

Depending on the situation, I use either of two methods: a 2-56 screw
and nut or a mini-tie-wrap. Both work well. Proper use of the tie-wrap
can keep the two mating connectors as well.

73 de K2ASP - Phil Kane
Elecraft K2/100 s/n 5402

From a Clearing in the Silicon Forest
Beaverton (Washington County) Oregon

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