Application Specification

114-64005

RAPID LOCK* Single-Pole
Quick-Connect/Disconnect Bus Bar Connectors

19 AUG 21 Rev B1NOTE
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and inches].
Unless otherwise specified, dimensions have a tolerance of ±0.13 [±.005] and angles have a tolerance of ±2°. Figures andillustrations are for identification only and are not drawn to scale.

1. INTRODUCTION
This specification covers the requirements for application of RAPID LOCK single-pole quick-connect/disconnect
bus bar connectors used in bus bar and backplane power distribution applications. The connector consists of acrown socket and pin contact. The connector is available in screw mount (using a screw and washers) andswage mount (using an integral press-fit knurl and washer) for mounting to a bus bar or backplane.
The crown socket is a right-angle configuration and is available in sizes 8, 4, 2, and 12. The crown socket
consists of a housing (with a cap) and a body. The housing contains a crown contact and contact cavity thatfeatures retention clips designed to hold the pin contact in the crown socket. The pin contact features a seating
flange designed to support the pin contact on the mounting surface. The pin contact contains a crown band thatprovides stable electrical connection. When the pin contact is fully inserted into the crown socket, the retention
clips engage the locking feature of the pin contact to prevent accidental unmating.
A right-angle insulation boot is available to provide additional insulation for the cable. The insulation bootaccommodates cable terminating to crown socket sizes 8, 4, and 2. The insulation boot is available in variouscolors for indicator requirements.
The crown socket is designed to be crimped onto cable using manual or hydraulic tooling.
When corresponding with personnel, use the terminology provided in this specification to facilitate yourinquiries for information. Basic terms and features of this product are provided in Figure 1.

Screw Mount Connector
Crown Contact

Insulation Boot

Swage Mount Connector

Body

Body
Crown Contact

Crown Socket

Head

Crown Socket
HousingCapHousing

Cap

Cable Exit End
Crimp Barrel

Pin Contact

Seating Flange
Knurl

Locking Feature
Crown Band

Flat Washer

Crimp Barrel
Seating Flange
Knurl

Pin Contact
Locking Feature

Reducing Bushing

Crown Band

Flat Washer
Conical Washer

Screw
Restriction of Hazardous Substances (RoHS) Compliant
Figure 1© 2021 TE Connectivity family of companies
All Rights Reserved*Trademark

TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752

This controlled document is subject to change.
For latest revision and Regional Customer Service,visit our website at www.te.com.

TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product, and/or company names may be trademarks of their respective owners.

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2. REFERENCE MATERIAL
2.1. Revision Summary
Initial release of application specification

2.2. Customer Assistance
Reference Product Base Part Number 6648228 and Product Code D040 are representative ofRAPID LOCK quick-connect/disconnect bus bar connectors. Use of these numbers will identify the product line
and expedite your inquiries through a service network established to help you obtain product and toolinginformation. Such information can be obtained through a local Representative or, after purchase, by calling
PRODUCT INFORMATION at the number at the bottom of page 1.

2.3. Drawings
Customer Drawings for product part numbers are available from the service network. If there is a conflict
between the information contained in the Customer Drawings and this specification or with any other technicaldocumentation supplied, the information contained in the Customer Drawings takes priority.

2.4. Specifications
Product Specifications (108-series) provide product performance and test information. There no specifications
available that pertain to this product.

2.5. Instructional Material
Instruction Sheets (408-series) provide product assembly instructions or tooling setup and operation
procedures and Customer Manuals (409-series) provide machine setup and operating procedures. There is no
instructional material that pertains to this product.

3. REQUIREMENTS
3.1. Safety
Safety interlocks and/or insulating devices must be designed into the system to avoid inadvertent electricalshock.
DANGERTo avoid personal injury, the electrical system must be de-energized before installing or removing any connector and before
mounting or removing connectors from the bus bar or backplane.

3.2. Chemical Exposure
Do not store connectors near any chemical listed below as they may cause stress corrosion cracking in thematerials.
Concentrated SulfurChlorine

3.3. Material
The body of the crown socket is made of tellurium copper plated with silver over nickel; the housing is made ofthermoplastic, and the crown contact is made of beryllium copper plated in gold over nickel. The pin contact ismade of tellurium copper alloy plated with silver over nickel. The screws and washers are made of steel platedwith nickel. The insulation boot is made of fire retardant grade polyvinyl chloride (PVC).

3.4. Cable Selection and Preparation
A. Selection
The crown socket accepts stranded copper cable sizes listed in Figure 2.

B. Preparation
The insulation boot (available for crown socket sizes 8, 4, and 2) must be installed onto the cable before
stripping the cable. The cable exit end of the boot is molded solid and must be cropped so that theRev B1

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114-64005
diameter of the boot allows the boot to slide onto the cable. Since the boot in not intended to protect thecable or pin contact from ingress of dust or water, a loose fit is permissible. The boot must not bedamaged during cropping. See Figure 2.
The end of the cable exiting the head of the insulation boot must be stripped. Proper cable strip length isnecessary to properly insert the cable into the crown socket. The strip length of the cable is given inFigure 2.
CAUTION
Care must be taken not to nick, scrape, or cut any part of the cable during the stripping operation.

Note: Not to Scale

Cable

Cable Strip Length(See Table)

Cable Exit End ofInsulation Boot Cropped
Head of Insulation Boot

CROWN SOCKETSIZECABLESIZE (AWG)

STRIP LENGTH (-0/+0.51 [-0/+.020])

12, 1006.86 [.270]

8, 6012.7 [.500]

48, 6, 4012.7 [.500]

22, 0, 1/0

15.24 [.600]

12 mm

3/0025.0 [.984]

8Figure 2

3.5. Reducing Bushing
For cable size 12 AWG, the reducing bushing must be installed onto the cable, then the end of the cable andthe reducing bushing must be inserted into the crimp barrel of the pin contact. The reducing bushing must be
flush with the top of the crimp barrel.

3.6. Termination
The terminated crown socket must meet the following requirements:

A. Cable Insulation Location
The insulation of the cable must not enter the body of the crown socket. See Figure 3.

B. Crimp Location
The crimp must be centered on the body of the crown socket. See Figure 3.

C. Tensile Strength
Crimped crown sockets must hold the cable firmly and have a crimp pull-out test value specified in Figure 3.

3.7. Bus Bar and Backplane
A. Material and Thickness
The bus bar or backplane thickness shall be 3.0 [.118] or 3.18 [.125]. Call PRODUCT INFORMATION atthe number at the bottom of page 1 for suitability of other thicknesses.

Rev B13 of 11114-64005

Insulation Boot (Ref)
Crimp Centered on Body

Cable Insulation Does Not
Enter Body

CABLE SIZE(AWG)TENSILE STRENGTH (N [lbs])

12, 10311.5 [70]8400.5 [90]6445.0 [100]4623.0 [140]2801.0 [180]0, 1/01112.5 [250]3/01557.5 [350]Figure 3

B. Hole Dimension and Circuit Pad Thickness
The hole in the mounting surface for the pin contact must be drilled and plated through to specificdimensions. The plating type and finished hole size must be as stated to provide unrestricted insertion ofthe pin socket. The circuit pad thickness must be as stated. See Figure 4.

Backplane or Bus Bar (Ref)
Pad Height: 3.00±0.25 [.118±.001]

Finished Hole Diameter(After Plating)
0.051±0.025 [.002±.001]
Recommended Copper Plating (Max Hardness 150 Knoop)

Drilled Hole Diameter (Ref)0.005 [.0002] Tin Over 1.27 [.000050] Nickel Plating

MOUNTING
SURFACECONNECTOR
MOUNTING TYPE

Swage-Mount
Backplaneor Bus Bar
Screw-Mount

CROWN SOCKETCONTACT SIZEFINISHED HOLE DIAMETER(After Plating)8

6.60+0.07/-0.03 [+.0027/-.001]46.60+0.07/-0.03 [+.0027/-.001]

29.40+0.08/-0.03 [+.0031/-.001]

12 mm

12.00+0.08/-0.03 [+.0031/-.001]

4

6.60+0.07/-0.03 [+.0027/-.001]

2

9.40+0.08/-0.03 [+.0031/-.001]

Figure 4

Rev B14 of 11

114-64005
3.8. Mounting
A. Screw Mount Connector
The screw mount pin contact must be mounted onto the bus bar or backplane according to the following:— The seating flange of the pin contact is fully seated on the mounting surface. When seating a pin
with knurl feature, please refer to below procedure and Figure 5.
1. Insert the location dowel into bus bar or backplane support fixture. (Optional procedure, toprevent pin fall from bus bar or backplane when move bus bar or backplane with pin)
2. Lay bus bar or backplane onto support fixture.
3. Put Rapid Lock Pin onto bus bar or backplane hole.
4. Place the seating tool onto Rapid Lock Pin, the seating flange of the pin must be touched byseating tool. (Optional Procedure for small top surface pins)
5. Apply a force to pin or seating tool to press the pin into bus bar or backplane until the pin flange isfully seated on the mounting surface. The application tooling (such as an arbor press) used to seat
Rapid Lock pin must provide adequate downward force to insert pin into bus bar or backplane holes.
The seating flange of the pin contact is fully seated on the mounting surface

Figure 5— The flat washer is over the knurl of the pin contact and against the mounting surface.
— The concave side of the conical washer is facing the flat washer and against the flat washer.
— The screw is secured to the pin contact to a torque given in Figure 6.

Rev B15 of 11

114-64005

Mounting Screw Mount Connector
Seating Flange of Pin Contact
Against Mounting Surface

Flat Washer Against Mounting Surface
Concave Side of Conical Washer
Facing Flat Washer and Against
Flat Washer

Front of Mounting Surface

CROWN SOCKETSIZETORQUE(Nm [in.-lbs])

4

2.1

22.9

Screw Secured toPin Contact
Figure 6

B. Swage Mount Connector
The swage mount pin contact must be mounted onto the bus bar or backplane according to the following.
Before swage:— A support fixture must be used to support the pin contact during swaging. The pin contact must sit
freely in a hole in the support fixture.
— The seating flange of the pin contact is fully seated on the mounting surface.
After swage:— The seating flange of the pin contact is against the mounting surface. The portion of the pin contactthat protrudes from the front of the mounting surface is within the dimension range given in Figure 7.
— The flat washer is over the protruding portion of the pin contact and against the mounting surface.
The flat washer must be unable to rotate.
— The pin contact is not distorted or damaged, and the plating of the pin contact is not broken.
Mounting Swage Mount Connector
Seating Flange of Pin Contact
Against Mounting Surface

2.8-3.3 (After Swage)
Pin Contact

CROWN SOCKETSIZETORQUE(Nm [in.-lbs])

8

2.0

4

3.5

2

4.5

12 mm

5.0

Flat Washer

Front of Mounting Surface
Figure 7— The mechanical strength of the swaged joint meets the torque value given in Figure 7.
— The electrical resistance of the swaged joint should be determined.

C. Pressing force of mounting
Typical value of pressing the pins into PCB or bus bar by simulation analysis.

Rev B16 of 11

114-64005
MOUNTING
SURFACECONNECTOR
MOUNTING TYPE

Swage-Mount
Backplaneor Bus Bar
Screw-Mount

CROWN SOCKETCONTACT SIZETYPICAL PRESSING FORCE
(N)

81500

41500

21800

12 mm

4000

41500

21800

3.9. Mating and Unmating
The contact cavity of the crown socket must be aligned with the pin contact, then the crown socket pushedstraight onto the pin contact until the crown socket is against the seating flange of the pin contact and thelocking feature snaps into place (there should be an audible click).
After mating the crown socket to the pin contact, the crown socket must be pulled back lightly to ensure that thecrown socket is fully seated. See Figure 8.
A guideline for the average force needed for mating and the average force needed for unmating is given in
Figure 8.

3.10. Installing Insulation Boot
The insulation boot must be pulled over the crown socket. The head of the insulation boot must be against thehousing of the crown socket. The pin contact must not be exposed at the opening of the boot. See Figure 7.

3.11. Repair
Components of the connector are not repairable. Damaged or defected components must not be used.

Rev B1CROWN SOCKETSIZEMATING FORCE
N (lb-force)

UNMATING FORCE
N (lb-force)

8

19.32 [4.343]

10.63 [2.389]

4

29.04 [4.505]

16.08 [3.615]

2

48.43 [10.89]

19.53 [4.390]

12 mm

100 [73.75]

20 [14.75]

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Seating Flange of Pin Contact
Mounting Surface

Locking Feature of Pin Contact

Swage Mount Connector

Pin Contact Not Exposed at
Opening of Insulation Boot

Screw Mount Connector

Head of Insulation Boot Sitting
Against Housing of Crown
Socket with No Metal Parts ofPin Socket Exposed

Figure 8

4. QUALIFICATIONRAPID LOCK quick connect/disconnect bus bar connectors are Listed by Underwriters Laboratories Inc. (UL) inFile E28476.

5. TOOLINGTooling part numbers are given in Figure 9.
NOTE
For industry-standard tooling, consult manufacturer's literature for information on using the tooling.

5.1. Cropping Insulation Boot
A scissors should be used to crop the molded end of the insulation boot to allow it to be installed onto thecable.

5.2. Crimping Crown Socket
A. Hand Tools
The electric-hydraulic hand tool produces an output force of 62 kN.
Industry-standard battery-operated crimping tools and hydraulic hand crimping tools are available.

B. Power Units
Industry-standard power units are available.

C. Die Sets
Industry-standard die sets are available to be used with the hand crimping tools.

Rev B18 of 11

114-64005
Contact information for recommended industry-standard tooling is as follows:
STANLEY-DUBUIS at www.dubuis.com
Pacific Industrial Components (PICO) Corporation at www.picotools.com

5.3. Swaging
CAUTION
The swage connector pin contacts must be loaded and swaged individually using a fly press or multi-loaded and swaged
collectively using a power press. During loading, pin contacts must be adequately supported to prevent swelling of the pincontact shank, distortion of the pin contact, or damage to the pin contact plating.

A. Fly Press
A good-quality commercially-available fly press must be used to secure the pin contact to a bus bar andwhen swaging individual pin contacts.
NOTE
A commercially-available power press should be used when swaging multiple pin contacts.

5.4. Removal
The removal tool is available to remove the pin contact from the crown socket. The removal tool is suitable forall connections to crown socket sizes 8, 4, and 2. This tool is needed to depress the crown socket internalretention clips and release them from the locking feature of the pin contact. This tool is designed to release theretention clips without deforming them.
Before removing the pin contact from the crown socket, all power must be turned off. The removal tool must be
inserted between the crown socket and the mounting surface.
DANGERTo avoid personal injury, all power to the connectors must be turned OFF.

INDENTER HEADLOCATORDIE SET for
STANLEY-DUBUIS Hand
Crimping Tools

12414DA-4713-5

4713-1—10414DA-4713-4

4713-1—414DA-8N or 414DA-4713-2(M22520/23-02)

4046A or 4713-1(M22520/23-09)

2161347-1

414DA-4713

4713-1

2161348-1

4

414DA-4713

4711-1

2161349-1

2

414DA-4711-2

4711-1

2161350-1

514DA-1/0N.290(M22520/23-05)

12159(M22520/23-13)—

514DA-4/0N.430

12158-SPG

2161350-1

WIRE SIZE(AWG)

860, 1/0
3/0

PICO CORPORATION CRIMP TOOLING (Military Standard)
POWER UNIT

Series 400(M22520/23-01)

Series 400 or Series 500(M22520/23-01)

STANLEY and DUBUIS are trademarks of their respective owners.

Rev B19 of 11

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AUTOPRESS 62 Electro-HydraulicBattery-Operated Hand Crimping Tool 1629804-1

STANLEY-DUBUIS BPP062
Pistol Battery-Operated
Hand Crimping Tool

STANLEY-DUBUIS BPL062
Inline Battery-Operated
Hand Crimping Tool

Power Unit (Ref,Refer to Table)

Typical Fly Press (Refer toInstructional Material Included with Press)

STANLEY-DUBUIS D62
Hydraulic Hand CrimpingTool

Indenter Head (Ref,Refer to Table)Removal Tool
1857376-1

Die Set for STANLEY-DUBUIS
Hand Crimping Tools(Ref, Refer to Table)

Locator (Ref,Refer to Table)

Figure 9

Rev B110 of 11

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6. VISUAL AID
The illustration below shows a typical application of RAPID LOCK quick-connect/disconnect bus bar
connectors. This illustration should be used by production personnel to ensure a correctly applied product.
Applications which DO NOT appear correct should be inspected using the information in the preceding pagesof this specification and in the instructional material shipped with the product or tooling.

INSULATION BOOT MUSTNOT BE DAMAGEDCABLE MUST NOT BEDAMAGED IN ANY WAY

INSULATION BOOT MUSTNOT BE DAMAGEDCROWN SOCKET MUST BE FULLYSEATED AGAINST SEATINGFLANGE OF PIN CONTACTHEAD OF INSULATION BOOTMUST SIT AGAINST HOUSINGOF CROWN SOCKETSEATING FLANGE OF PINCONTACT MUST BE AGAINSTMOUNTING SURFACEMETAL PARTS OF PIN CONTACTMUST NOT BE EXPOSED ATOPENING OF INSULATION BOOTFIGURE 10. VISUAL AIDRev B111 of 11