Undervoltage/powerpole issue

This is what the power connector should be.
https://www.neutrik.com/en/neutrik/products/powercon/powercon-32-a

I found on our club 6600 that the power-pole was quite loose; it would pull out when moved on the rack.
Increasing the contact pressure (bending both pins) fixed the problem.  It seems the batch of PP connectors FRS used were not formed correctly but a few seconds of tightening fixes that.

Dan, your description of a spade & a leaf spring implies 2 metal pieces inside the housing.  There is only one.  The contact is a flat piece of metal ("spade" if you will) with a curved bump on one end,  Sort of the same shape as looking at the edge of a fork.

I have never had issues with an intermittent connection, but have had issues with a voltage drop across the contacts.  I bump my power supply voltage up a bit to compensate. -- 73, Ray, K9DUR

If you make your own powerpole cables, you quickly learn to make sure the metal contacts are pushed in far enough.  You should be able to look in the connector end and see the tab.  If not, they will not mate reliably.

Did you just replace the contacts on the cable or did you also change the contacts/connector on the radio?

The physical limitation is the limited area of the connector.  One way to address would be a second set of PP connectors on the Flex in parallel.  Then we could easily run parallel #10 cables from the supply.  Icom makes it very easy to do this since they already run parallel conductors.  Just a simple modification of their connector allows parallel cables back to the supply.

I was going to be silent on this topic but decide it was worth adding some comments. If there is ever going to be a weak link in a power system, it is going to be at the connector. If anyone really thinks one "good" connector system is better then another, they are fooling themselves. Every connector system has a basic issue, It is a connector. Mechanically, at best there are three contact points and when one fails you hope that there is another that reconnects. That all said, every connector design that you use MUST use only the OEM product or you open yourself up to sub-par performance. You do get what you pay for and cheaper usually means someone is trying to "rip off" the OEM. It is a **** shoot. You might get lucky and find a good supplier but in most cases the OEM gets a bad rap for something that is not their fault. If in a high vibration service, mobile, crimp your connectors using only what the manufacture recommends. Follow what they say, they have spent lots of money testing their designs. If in a non-vibration environment, QTH, solder your wires to your connectors. But do this before you insert the metal parts into the plastic parts or you will for sure cause other issues. 

I for one appreciate that Flex chose a common connect design - Anderson Powerpole. Done right, they perform flawless. If you have an issue with the connectors and wire harness supplied by Flex, CALL THEM. Something is wrong and in my case, they have always done the right thing. You may have gotten a bad one. The world is not perfect. BUT if you are using your cable, time for some more education. After all, that is what Ham Radio is really about. If we are not learning, what value are we getting?

I have 40 plus years of testing automotive and heavy vehicle electronic system and have tested every connector systems you can imagine. I can fail any of them if they are not built 100% to what the OEM recommends. But if done right, you will enjoy many years of no issues. Good supplier know that they are doing. 

If you still think you have a better idea, go for it. Change the connectors on you Flex Radio. Just don't blame Flex if you burn up your so call Better Connector system. Mechanical connector locks have their purpose but remember, there is still a mechanical/electrical connection inside that are usually not improved by an external lock. Thank you all for those who suggested cable restraints.

This is an open community so expressing your opinions that one connector is better than another is your right but it is you opinion unless you have real test data to show there is a difference. And by this I mean thousands of hours in test environments that measures the multiple parameters at their extremes..  

The key word is CONNECTOR which is the problem not the type of connector the rest of the babble is JUST someones opinion.

I have used MOLEX connectors in commercial equipment and have actually had them catch fire from getting hot when the Spring goes out of the socket and or oxidize so they are definitely not the answer.
My commercial carrier involves probably more then 2000 2-way radio's, over 300 Television Transmitters, Motor vehicle Electrical systems repair and a HAM since 1982 so have seen thousands of connector and no MATTER what kind of connector you use if it is NOT sealed, does NOT have solid Mechanical and Electrical non oxidizing metal like gold they will oxidize and break down and have resistance which produces heat. 


The Power Pole connectors DO have the capability with there built in Strain relief into the connector which is the Small Holes half way through the connector so when both Positive and Negative are slid together it makes a round hole that you can put a small zip tie or Plastic covered tie Wire  to the opposite mating side and locks them, BUT unfortunately FLEX put the connector to far into the Cabinet to be able to get to the hole on the Radio side with out pulling the cover and trying to fish it through the hole and through the chassis hole. 

Anyway this debate can go on forever about connectors with all the same outcome (THEY WILL BREAKDOWN OVER TIME)

73's
Bret
WX7Y

Hi John,

RE: " But if your warranty has run out and and like overkill like me and don't mind an easy DIY project these are great! "

Did you make the swap to those terminals?  Or plan to?  It would be nice to see some pictures of the before and after.   It has been a while since I had the cover off of my 6700 but don't remember seeing much room around the power connectors.  

Regards, Al / NN4ZZ  
al (at) nn4zz (dot) com
Win 10 SSDR V2.4.9

Actually, there are two pieces of metal in each connector. The spade is attached to the incoming wire and a spring in the housing holds the spade in place.

The Anderson brand connectors work pretty well, but like most stuff any more there are inexpensive imports that will work, just not very well.

I had the power supply connected to  distribution block, but the loss was excessive on transmit, due to the high current flow. I ended up attaching the flex directly to the power supply and a separate connection to the distribution block for all the low current items.Then, as above, I adjusted the output voltage of the power supply to maintain the desired voltage to the flex during transmit.  (13.8v +- 15%).

The Power Poles became the norm for much of ham radio to alleviate the multitude of adapters needed to connect various radios and components together during field/emergency operations involving several co-located radios. The convention is "Tongue top, red right"

Why is it that a "Flex Radio" is never the problem with flex management?

I dealt with a resetting problem over a year before any help from flex was offered, I was told to buy all new stuff and I did.. $900..... problem still exist like I said it would so finally they exchanged radio and its been fine.   Wish I had my 900 back.

Ok so onto the problem here.

One of the connectors, either in the radio or ALL the other connectors you have used are assembled incorrectly.


Answer is pretty clear to me.