How To Assemble Powerpole Connectors: A Step-By-Step Pictoral Guide
I love Powerpoles. I powerpole everything and anything I can. But each time I do it, well, it feels like the first time. So here are the steps to help keep somewhat you, but mostly me, in order. First off, a Powerpole is a DC power connector that consists of a metal wire crimp contact (available commonly in 15A, 30A, and 45A sizes which are based on the gauge of the wire) with a hook on the end, and a rectangular plastic housing. Within the plastic housing is a flat metal spring which the hook of the wire crimp contact catches on, thereby securing the wire to the connector housing. The assembled Powerpoles then fit like legos into one another to allow for the flow of electricity from source to load.
The Steps to Assembling Power Poles:
- Decide on the correct orientation of the Powerpole assembly.
- Prepare the power cord wires by identifying which is positive, and stripping the ends to the proper length.
2. Use a crimping tool for Powerpoles to crimp the metal contact onto the wire. Note that the Tricrimp tool I use has different slots for 15A, 30A, and 45A connector sizes, so be sure to use the correct one. The hook part of the metal contact should point downward in relation to the lettering on the tool. Squeeze down on the handle until you feel the device relax. The wire and metal contact on the right side of the screen in the picture above has been crimped, whereas the one of the left has not been crimped.
3. The metal contact of the Powerpole has a hook that slides over a metal flat spring within the plastic housing. If you look carefully inside the Powerpole below, you can see the metal flat spring.
Press the metal crimped contact into the plastic housing of the Powerpole. Please note that the wire has been omitted for the demonstration photos below and the roof of the powerpole has been purposely broken off in order to visualize the process. Make sure that the hook is pointed down toward the side that has the metal flat spring in it. You will encounter resistance about 2/3rds of the way into the housing; push through that resistance firmly and steadily. The hook of the metal contact will snap into place over the flat spring.
4. The Powerpole plastic housing has slots carved into their sides so that the postive and negative connectors can physically pair with one another if you wish them to.
If you oriented everything correctly at the beginning, this configuration should work with most other standard powerpole connections.
And just like that, the new transceiver is one step closer to getting out in the field…