![background image](http://html1.mh-extra.com/html/eaton/roughneck-if-1683/roughneck-if-1683_installation-and-maintenance-information_4351490004.webp)
Section 10: Maximum Allowable Amperage Calculation
Shell size
W - max. wattage at 55°C
12
7.4
16
13.5
20
15.6
24
16.1
C24
27.1
28
22.6
Table 6. Maximum Heat Dissipation Per Connector
Maximum total amperage per shell is limited by the
temperature threshold of the internal components. Maximum
amperages in Table 5 may change when multiple contacts are
used in one shell. If using multiple conductors, the dissipated
heat [watts] should not exceed the levels in Table 6. The
formula below can be utilized to calculate dissipated heat.
WARNING
SHOCK HAZARD
Note: Maximum heat dissipation levels calculated at max.
ambient temperature rating of 55°C.
Formula:
D: Total heat dissipation per shell [watts]
W: Total heat dissipation per set of contacts of the
same size / gauge [watts] and same current [amps]
I: Expected current per contact not to exceed the
max. current outlined in Table 5 [amps]
R: Contact resistance [ohms]
N: Number of conductors
D: W1 + W2 + W3 + … Wn
W = I^2 x R x N
D ≤ Watt Values (Table 8)
Table 8. External Cable Jacket Strip Length
Jacket strip length
(multi-conductor cable)
inches
mm
12 shell
1.70
63.50
16 shell
4.50
114.30
20 shell
4.75
120.65
24 shell
5.00
127.00
28 shell
5.00
127.00
Section 11: Table References
Table 7. Conductor Strip Lengths
Contact size
Conductor strip length
AWG
(mm
2
eqv.)
inches
mm
23
0.26
0.586
12.88
16
1.3
0.586
12.88
13
2.62
0.585
12.85
12
3.3
0.585
12.85
10
5.3
0.668
14.96
8
8.4
0.839
19.30
4
22
0.896
22.76
1/0
53
1.417
35.99
4/0
107
1.425
36.20
313 MCM
159
1.85
44.45
444 MCM
227
1.85
44.45
535 MCM
273
1.85
44.45
777 MCM
394
1.85
44.45
Copyright © 2018 Eaton’s Crouse-Hinds Division
IF 1683 • 08/18
Page 7
Copyright © 2018 Eaton’s Crouse-Hinds Division
IF 1683 • 08/18
Page 8
Shell size
Thread
Metric (N-m)
English values (ft.-lb.)
12
LH thread
34.0
25
Coupling nut
20.3
15
Metric gland (M25)
30.0
22
16
LH thread
40.5
30
Coupling nut
27.1
20
Metric gland (M40)
45.0
33
20
LH thread
47.5
35
Coupling nut
33.9
25
Metric gland (M50)
55.0
41
24
LH thread
54.0
40
Coupling nut
40.7
30
Metric gland (M63)
67.0
50
28
LH thread
61.0
45
Coupling nut
47.5
35
Metric gland (M75)
80.0
59
Panel mount
M5 panel bolt
5.4
4
Mechanical clamp
Clamp bolts
3.4
2.5
All sizes
Coupling nut set screw*
10.8
8.0
Contact size
Crimp tool
Positioner/die #
23 AWG
CH300-25 A
CH682-1
16 AWG
CH300-25 A
CH682-1
13 AWG
CH300-25 A
CH684-1 socket
CH683-1 pin
12 AWG
CH300-25 A
CH684-1 socket
CH683-1 pin
10 AWG
CH300-25 A
CH684-1
8 AWG
13100A T&B 14 ton hydraulic crimper head or equivalent
15520 / 21
4 AWG
13100A T&B 14 ton hydraulic crimper head or equivalent
15513 / 37
313 MCM
13100A T&B 14 ton hydraulic crimper head or equivalent
15512 / 76
444 MCM
13100A T&B 14 ton hydraulic crimper head or equivalent
15505 / 99H
535 MCM
13100A T&B 14 ton hydraulic crimper head or equivalent
15515 / 106H
777 MCM
13100A T&B 14 ton hydraulic crimper head or equivalent
15504 / 115H
*T&B tool part numbers not available through Crouse-Hinds.
Contact size
Removal
Insertion
Tool part no.
Tool part no.
8
CH 2-8250
CH 1265
10
CH 2-8250
CH 1205
12
CH 2-8250
CH 1000-12
13
CH 2-8250
CH 1000-16
16
CH 2-8250
CH 1000-16
23
CH 2-8250
CH 1000-16
Pin size
Termination
style
Max.
current (A)
R - pin assy.
resistance (ohms)
23 AWG
Crimp
1 AMP
0.0218
16 AWG
Crimp
18 AMP
0.0053
13 AWG
Crimp
26 AMP
0.0028
12 AWG
Crimp
30 AMP
0.0021
10 AWG
Crimp
40 AMP
0.0013
10 AWG
Pressure
40 AMP
0.0014
8 AWG
Crimp
55 AMP
0.00086
8 AWG
Pressure
50 AMP
0.0011
4 AWG
Crimp
90 AMP
0.00036
4 AWG
Pressure
73 AMP
0.00088
1/0
Pressure
130 AMP
0.00040
4/0
Pressure
198 AMP
0.00023
4/0
Pressure
252 AMP*
0.00010*
313 MCM
Crimp
502 AMP
0.0000515
350 MCM
Solder
290 AMP**
0.000072**
444 MCM
Crimp
722 AMP
0.0000414
535 MCM
Crimp
815 AMP
0.0000374
777 MCM
Crimp
1030 AMP
0.0000254
Table 5. Maximum Current and Resistant Values
Table 12. Mod I – Pressure Contact Torque
Requirements
Contact/conductor size/
AWG (mm)
Torque req.
in./lbs. (N-m)
4/0 (120.00)
100 (11.3)
1/0 (50.00)
50 (5.7)
#4 (25.00)
20 (2.3)
#8 (10.00)
15 (1.7)
#10 (6.00)
15 (1.7)
*252 amp and 0.000010 ohm rating is for C28-R44 insert only.
**290 amp and 0.000072 ohm rating is for C28-43 terminated
with 262 MCM cable or larger.
**
Note:
Quality of solder termination greatly affects resistance
value. Solder in accordance with J-STD-001.
Table 9. Torque Values for Shell Component Assembly
Table 10. Contact Crimping Tools and Dies
Table 11. Contact Insertion and Removal Tools
*All shell sizes use a SAE
1/8 inch hexagon key per
ASME B18.3.