Copyright © 2018 Eaton’s Crouse-Hinds Division
IF 1688 • 08/18
Page 5
Section 7: Contact Insertion Instructions (excluding single pole)
Copyright © 2018 Eaton’s Crouse-Hinds Division
IF 1688 • 08/18
Page 6
1.
Locate position No. 1 on back of insert (1).
2.
Take correct numbered contact (2) (see step 4, Section
6) and insert into position 1, pushing by hand until
feeling resistance. Complete installation by using correct
insertion tool (3) per Table 5 to press contact (2) until
hearing and feeling the contact “click” into place.
3.
Repeat steps 1 & 2 for each location # on the insert (1).
WARNING: Even if a location is not being used, a blank
pin/socket must be inserted to maintain environmental
integrity.
Section 8: Crimping Instructions for Single Pole Contacts
A. Crimping Instructions:
1.
Prepare cable, cutting to length as needed.
2.
Strip outer jacket to length per Table 1.
3.
Take crimping tool per Table 4 and install correct die based on
pin size being crimped.
4.
Place stripped end of conductor into contact socket, verify that
between 1 and 3 mm of bare copper is exposed between end
of contact and insulation.
5.
Place contact with wire into crimping tool, aligning die faces
with 1st set (see picture) of alignment marks.
6.
Operate tool until the contact is crimped and tool releases.
7.
Move crimped contact to 2nd set (see picture) of alignment
marks and repeat step 6.
1st Set Alignment Marks
2nd Set Alignment Marks
Section 9: Maximum Allowable Amperage Calculation
Shell
size
Max. wattage
40°C ambient
90°C rated wire
Max. wattage
40°C ambient
110°C rated wire
Max. wattage
40°C ambient
125°C rated wire
12
12.8
13.2
13.2
16
20.7
27.4
28.9
20
23.6
31.1
33.1
24
35.6
46.8
49.7
28
22.1
28.9
33.2
Table A. Maximum Current and Resistant Values
Pin size
Max. current
(A)
Resistance
(ohms)
23 AWG
1 AMP
0.0218
16 AWG
18 AMP
0.0053
13 AWG
26 AMP
0.0028
12 AWG
30 AMP
0.0021
10 AWG
40 AMP
0.0013
8 AWG
55 AMP
0.00086
4 AWG -
Pressure
90 AMP
0.00056
4 AWG -
Crimp
95 AMP
0.00036
1/0
155 AMP
0.00032
4/0
225 AMP
0.00018
313 MCM
636 AMP
0.0000515
444 MCM
796 AMP
0.0000414
535 MCM
898 AMP
0.0000374
777 MCM
1135 AMP
0.0000254
Table B. Maximum Heat Dissipation Per Connector
Maximum total amperage per shell is limited by the
temperature threshold of the internal components. Maximum
amperages in Table A 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 B. 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 40°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 A [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 2)
Section 10: Table References
1. Insert
2. Contact
3. Insertion Tool
1.
Locate the conductor and related contact.
2.
Insert conductor into the opened termination side
of the contact.
3.
Tighten screw to torque value shown in Table 6.
4.
Repeat for all contacts.
Mod II (Crimp Style)
Mod I (Pressure Style)
Table 1. 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
