Assembling Powerpole Connectors

These simple instructions assume that you are using Red-Black "zip" cord with stranded conductors (12 to 16 gauge).

Soldering Powerpole Contacts

Use your wire stripper to prepare both conductors of one end of the length of zip cord. I strip each conductor back 1/4".

Place the first contact over the stripped Red wire. Note the orientation of the contact's "blade" since there's only one way the contact will fit into the housing.

Position the zip cord and contact on a flat surface suitable for soldering and secure it for soldering with something heavy.

With a medium wattage soldering iron*, carefully apply heat to the contact. Within a few seconds apply solder and allow it to flow into the contact to completely "wet" the stranded conductors hidden inside the contact.

* I use a 40 watt pencil type iron with good success.

Once the solder appears where the insulation meets the contact, you've probably added enough solder to ensure a good connection.

Allow the contact to cool. Don't bump the wire or contact while it's cooling or you risk creating a cold solder joint that might fail later on.

Once the contact and wire has cooled, repeat the process with the Black wire and then follow the steps below to install the contact into the Powerpole housing.
 


Assembling the Powerpole Contacts into the Housings

Before inserting the pair of contacts into the housings, it's a real good idea to clean soldering residue off the contacts. Note the brown gunk on the contacts in the picture above.

Align the contacts with the Red and Black Powerpole housings as shown below. Reminder: There's only one way the contacts will fit into the housings.



Keeping the contacts straight, begin to insert them (together) into the Red and Black housings.



Slide the contacts in a little more and with a little luck, you'll hear two distinct "clicks" as the contacts lock into the housings.

You can test the "lock" by tugging a bit on the wires while holding the housings in your other hand.



That's all there's to it. Once you get the hang of it, you should be able to complete the soldering and assembly of a pair of Powerpoles in two minutes or less.



Hopefully, you'll find my instructions easy to follow. However, if you don't like my instructions, there are others to be found on the internet. You can also check out Anderson Power Product's assembly instructions.

Customer Websites NEW!

Electric Bike Kit Solutions  - E-bike kit solutions for your bicycle.

Hightekbikes - Electric bikes and eBike motor kits

Other Powerpole-related Websites

Anderson Power Products

ARRL's DC Power Distribution Presentation (requires PowerPoint)

West Mountain Radio's RigRunner Product Line

Amateur Radio Websites

Franklin County Amateur Radio Club (NC)

Raleigh Amateur Radio Society

Motorcycling Websites

Capitol BMW - Raleigh, NC

Carolina Euro - Greensboro, NC

Motorcycle skills training by MotoMark1

Tarheel Travelers BMW Motorcycle Club

Brian's Personal Motorcycling Blog

Moto-Farkle


A few words on Crimping Powerpole Contacts

Some folks prefer to crimp vs. solder their contacts. Anderson has a pricey crimper available, but the $10 Gardner-Bender GS88 (pictured) is just fine if you have strong hands.



Click here for a really nice comparison of different Powerpole Crimping Tools as compiled by the fine folks at NTRAK Modular Railroading Society.



So, what are you using Powerpoles for?

Let us know how you are using Anderson Powerpoles. Stories and pictures via email are always welcome.

We are constantly looking for ways to expand this website with additional resources, pictures and user-submitted web links.