Anderson Power Products 5915-BK PowerPole Contact Instruction Manual

1. Introduction

This manual provides essential instructions for the proper use, installation, and maintenance of Anderson Power Products 5915-BK PowerPole contacts. These contacts are designed for reliable electrical connections in various applications, supporting 10 or 12 AWG wire and rated for up to 75 amperes.

Please read this manual thoroughly before proceeding with installation or use to ensure safety and optimal performance.

2. Product Overview

The Anderson Power Products 5915-BK is a non-insulated copper contact specifically engineered for use with Anderson PowerPole connectors. Key features include:

• Wire Gauge Compatibility: Designed for 10 AWG (American Wire Gauge) and 12 AWG wires.
• Current Rating: Capable of handling up to 75 Amperes.
• Material: Constructed from high-conductivity copper for efficient power transfer.
• Connection Type: Crimp terminal for secure and durable wire attachment.
• Application: Integral component for creating custom PowerPole cable assemblies.

Figure 1: Anderson Power Products 5915-BK PowerPole Contact. This image shows a single copper contact, designed for crimping onto 10 or 12 AWG wire. The contact features a flat, spade-like end for insertion into a PowerPole housing and a cylindrical barrel for wire crimping.

3. Safety Information

Always observe the following safety precautions when working with electrical components:

• Disconnect Power: Ensure all power sources are disconnected before installing or servicing electrical connections.
• Proper Tools: Use appropriate crimping tools designed for the specified wire gauge and contact type to ensure a secure connection.
• Wire Gauge: Match the wire gauge to the contact's specifications (10-12 AWG) to prevent overheating or poor connections.
• Insulation: Although these contacts are non-insulated, ensure proper insulation is applied to exposed wires and connections after assembly, typically by using PowerPole housings.
• Professional Installation: If you are unsure about any aspect of the installation, consult a qualified electrician.

4. Setup and Installation

Follow these steps to properly install the 5915-BK PowerPole contact onto your wire:

1. Prepare Wire: Strip approximately 1/4 to 3/8 inch (6-9 mm) of insulation from the end of your 10 or 12 AWG wire. Ensure the wire strands are clean and untwisted.
2. Insert Wire: Insert the stripped end of the wire fully into the barrel of the 5915-BK contact. The wire strands should be visible through the inspection hole (if present) or reach the end of the barrel.
3. Crimp Contact: Using a suitable crimping tool for PowerPole contacts, crimp the contact barrel securely onto the wire. Ensure a firm, permanent connection. A good crimp will be mechanically strong and electrically sound.
4. Inspect Crimp: Visually inspect the crimp for any loose strands or improper deformation. Gently tug on the wire to confirm it is securely held by the contact.
5. Assemble into Housing (Optional): If using with PowerPole housings (sold separately), insert the crimped contact into the appropriate housing cavity until it clicks into place. Ensure correct polarity.

For optimal performance, always use a dedicated PowerPole crimping tool.

5. Operating Instructions

Once the contacts are properly crimped onto wires and assembled into PowerPole housings (if applicable), they are ready for use. PowerPole connectors are designed for quick and reliable connection and disconnection.

• Connecting: Align the PowerPole connectors (with contacts inserted) and push them firmly together until they lock. Ensure correct polarity (typically red for positive, black for negative).
• Disconnecting: Pull the PowerPole connectors apart with a firm, steady motion. Avoid pulling directly on the wires.

These contacts are designed for high current applications, ensuring minimal resistance and heat generation when properly installed.

6. Maintenance

Anderson Power Products 5915-BK contacts require minimal maintenance. However, periodic inspection can help ensure long-term reliability:

• Visual Inspection: Periodically check contacts and connections for signs of corrosion, discoloration, or physical damage.
• Cleanliness: Keep contacts free from dirt, dust, and moisture. Use a clean, dry cloth for cleaning.
• Secure Connections: Ensure that contacts remain securely seated within their housings and that crimps are still firm.
• Avoid Overloading: Do not exceed the 75 Ampere rating to prevent overheating and potential damage.

7. Troubleshooting

If you experience issues with your PowerPole connections, consider the following:

• Poor Connection/Intermittent Power:
  • Check crimp quality: Ensure the wire is securely crimped to the contact. Re-crimp if necessary.
  • Verify contact seating: Make sure the contact is fully inserted and locked into the PowerPole housing.
  • Inspect for corrosion: Clean any corrosion on the contact surfaces.
• Overheating Connections:
  • Check wire gauge: Ensure the wire gauge (10 or 12 AWG) is appropriate for the current draw.
  • Verify current draw: Confirm that the current flowing through the connection does not exceed 75 Amperes.
  • Inspect crimp: A poor crimp can lead to high resistance and heat.
• Difficulty Connecting/Disconnecting:
  • Check for debris: Ensure no foreign objects are obstructing the connection.
  • Inspect housing: Verify that the PowerPole housings are not damaged or deformed.

8. Specifications

9. Support Information

For further assistance or inquiries regarding Anderson Power Products, please refer to the official manufacturer's website or contact their customer support. Specific warranty information is not provided in the product data.

Manufacturer: Anderson Power Products, Inc.