The factory installed PowerPole connector was misaligned on my K3.  After
trying to make sure the connectors I made were correct, several times, I
discovered that the “flat” (with a small dimple) connectors were to far back
on the heavy piece of wire they are soldered to.  This prevents them from
extending all the way out to the proper position as required by the mating
PowerPole connector. Thus when connected the little humps had nor slide over
each other and were not fully engaged.  I heated up each of these two
factory installed connectors and slid them outward slightly – making sure
that they are PERFECTLY even with each other. This took several attempts. 
Once I had gotten perfect alignment with the PowerPole connector installed
in the K3 I achieved a good connection. It now takes about 3-5 pounds of
force to pull them apart.  Since the connector in the K3 is mounted on heavy
wire if they are not soldered in the correct position they will not fit in
the connector correctly.   AND since this wire has a 90 degree bend at the
back, it can keep the connector case from going all the way back and
preventing proper engagement of the mating connector.  The connector on the
flexible wire is not a problem as there is give between the two wires and
that can allow the connectors to be properly seated in the case for proper
alignment and connection with the mating connector. 

I believe that if the PowerPole on the K3 was installed on a short length of
flexible wire we would not be reading about this problem as it would not
exist.  Either Elecraft should test EVERY connector or mount the connector
on a short length or wire.

Rich,
KE0X




Don Brown-4 wrote:
> 
> Hi
> 
> PowerPoles can be locked together with a small 'U" shaped piece of stiff 
> wire run through the holes between the red and black blocks after plugging 
> in the connectors. I do this on my solar panel setup to keep the
> connectors 
> in place even if the wires get pulled.
> 
> 
> Thanks
> 
> Don Brown
> KD5NDB
> 
> 
> 

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