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Section 7: Contact Insertion Instructions (excluding single pole)
1. Insert
2. Contact
Mod II (Crimp Style)
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
IF 1688 • 08/18
Copyright © 2018 Eaton's Crouse-Hinds Division
3. Insertion Tool
Mod I (Pressure Style)
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.
2nd Set Alignment Marks
Section 9: Maximum Allowable Amperage Calculation
Table A. Maximum Current and Resistant Values
Max. current
Pin size
(A)
23 AWG
1 AMP
16 AWG
18 AMP
13 AWG
26 AMP
12 AWG
30 AMP
10 AWG
40 AMP
8 AWG
55 AMP
4 AWG -
90 AMP
Pressure
4 AWG -
95 AMP
Crimp
1/0
155 AMP
4/0
225 AMP
313 MCM
636 AMP
444 MCM
796 AMP
535 MCM
898 AMP
777 MCM
1135 AMP
Table 1. Conductor Strip Lengths
Contact size
AWG
(mm
2
eqv.)
23
0.26
16
1.3
13
2.62
12
3.3
10
5.3
8
8.4
4
22
1/0
53
4/0
107
313 MCM
159
444 MCM
227
535 MCM
273
777 MCM
394
Page 5
IF 1688 • 08/18
Resistance
(ohms)
Maximum total amperage per shell is limited by the
0.0218
temperature threshold of the internal components. Maximum
amperages in Table A may change when multiple contacts are
0.0053
used in one shell. If using multiple conductors, the dissipated
heat [watts] should not exceed the levels in Table B. The
0.0028
formula below can be utilized to calculate dissipated heat.
0.0021
Note: Maximum heat dissipation levels calculated at max.
0.0013
ambient temperature rating of 40°C.
0.00086
Formula:
D: Total heat dissipation per shell [watts]
W: Total heat dissipation per set of contacts of the
0.00056
same size / gauge [watts] and same current [amps]
I: Expected current per contact not to exceed the
max. current outlined in Table A [amps]
0.00036
R: Contact resistance [ohms]
N: Number of conductors
0.00032
D: W1 + W2 + W3 + ... Wn
0.00018
W = I^2 x R x N
D ≤ Watt Values (Table 2)
0.0000515
0.0000414
Table B. Maximum Heat Dissipation Per Connector
0.0000374
Max. wattage
Shell
40°C ambient
0.0000254
size
90°C rated wire
12
12.8
16
20.7
20
23.6
24
35.6
28
22.1
Section 10: Table References
Conductor strip length
inches
mm
0.586
12.88
0.586
12.88
0.585
12.85
0.585
12.85
0.668
14.96
0.839
19.30
0.896
22.76
1.417
35.99
1.425
36.20
1.85
44.45
1.85
44.45
1.85
44.45
1.85
44.45
Copyright © 2018 Eaton's Crouse-Hinds Division
WARNING
SHOCK HAZARD
Max. wattage
Max. wattage
40°C ambient
40°C ambient
110°C rated wire
125°C rated wire
13.2
13.2
27.4
28.9
31.1
33.1
46.8
49.7
28.9
33.2
Page 6
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