Powersafe Configuration Guide

Use this guide to find out about everything Powersafe.

Powersafe Connectors Explained

What are the types of Powersafe Connector?

A ‘Line Connector‘ or ‘Inline’ connector acts as the electrical plug for connection between an appliance and the power source. The line connector consists of an insulated casing with a single pole that fits into a Powersafe socket. The connectors are fitted with a spring loaded plastic cap that prevents accidental finger touching of the contact. Powersafe contacts are available to suit power cable from #4 AWG to 500 MCM (25mm² to 300mm²).

A ‘Panel Mount Connector‘ or ‘Mounted Connector’ acts as the electrical socket for connection with a Powersafe Line Connector. The Panel Mount connector is mounted onto a distribution board or panel through 4 fixing holes on the flange. The Panel Mounts are terminated with M12 threaded post to a standard lug. Panel Connectors are supplied fully assembled with an M12 nut and spring washer for secure connection.

Connector Gender Explained

Both Line and Panel Mount connectors are available as Source (Male) and Drain (Female).

Source (Male) connectors have a male contact and a female insulator.

Drain (Female) connectors have a female contact and a male insulator.

Line Connector Configuration Help

Termination: How are Powersafe Connectors terminated?

There are 2 types of termination for Powersafe; Set Screws and Crimp

Set Screw Terminations use standard set screws to secure the connector to power cable. This type of termination is considered temporary as screws can be removed with an Allen Key to remove the connector and reuse the cable. Set Screw Connectors have a standard 4/0 (120mm²) size and for #4 to 3/0 (95mm² – 25mm²) a reduction kit is used to fit the contact and cable.

Set Screw Terminations are available for cables up to 300MCM (150mm2), for larger cables, crimp terminations are available .

  
    Cable
    Nominal Conductor OD (mm2)
    Nominal Conductor OD (Inches)
    Reduction Termination Sleeve Kit
  

    #4 SC
    25
    0.233
    R25
  

    #2 SC
    35
    0.293
    R35
  

    #1 SC
    50
    0.33
    R50
  

    1/0 SC
    55
    0.369
     R70
  

    2/0 SC
    70
    0.412
     R70
  

    3/0 SC
    95
    0.5
     R95
  

    3/0 SC
    95
    0.5
     R95
  

    4/0 SC
    120
    0.53
     N/A
  

Cable	Nominal Conductor OD (mm2)	Nominal Conductor OD (Inches)	Reduction Termination Sleeve Kit
#4 SC	25	0.233	R25
#2 SC	35	0.293	R35
#1 SC	50	0.33	R50
1/0 SC	55	0.369	R70
2/0 SC	70	0.412	R70
3/0 SC	95	0.5	R95
3/0 SC	95	0.5	R95
4/0 SC	120	0.53	N/A

  
    Cable
    Nominal Conductor OD (mm2)
    Nominal Conductor OD (Inches)
    Reduction Termination Sleeve Kit
  

    #4 Type W
    25
    0.233
    R25
  

    #2 Type W
    35
    0.25
    R35
  

    #1 Type W
    50
    0.33
    R50
  

    1/0 Type W
    55
    0.369
    R70
  

    2/0 Type W
    70
    0.412
    R70
  

    3/0 Type W
    95
    0.49
    R95
  

    4/0 Type W
    120
    0.53
    N/A
  

Cable	Nominal Conductor OD (mm2)	Nominal Conductor OD (Inches)	Reduction Termination Sleeve Kit
#4 Type W	25	0.233	R25
#2 Type W	35	0.25	R35
#1 Type W	50	0.33	R50
1/0 Type W	55	0.369	R70
2/0 Type W	70	0.412	R70
3/0 Type W	95	0.49	R95
4/0 Type W	120	0.53	N/A

  
    Cable
    Nominal Conductor OD (mm2)
    Nominal Conductor OD (Inches)
    Reduction Termination Sleeve Kit
  
#4 DLO 2KV
    21.1
    0.262
    R25
  

    #2 DLO 2KV
    33.6
    0.315
    R35
  

    #1 DLO 2KV
    42.4
    0.375
    R50
  

    1/0 DLO 2KV
    53.5
    0.435
    R70
  

    2/0 DLO 2KV
    67.4
    0.465
    R70
  

    3/0 DLO 2KV
    85
    0.535
    R95
  

    4/0 DLO 2KV
    107
    0.581
    N/A
  

Cable	Nominal Conductor OD (mm2)	Nominal Conductor OD (Inches)	Reduction Termination Sleeve Kit
#4 DLO 2KV	21.1	0.262	R25
#2 DLO 2KV	33.6	0.315	R35
#1 DLO 2KV	42.4	0.375	R50
1/0 DLO 2KV	53.5	0.435	R70
2/0 DLO 2KV	67.4	0.465	R70
3/0 DLO 2KV	85	0.535	R95
4/0 DLO 2KV	107	0.581	N/A

Crimp Terminations have a different sized crimp bucket on the copper contact to allow a range of cable sizes. Crimp terminations allow for an incoming cable range of #4 to 600MCM (25mm² – 300mm².) Phase 3’s standard size is 4/0 & 500MCM (120mm² and 240 mm²), which for instance fits with standard sized single conductor power cable. We recommend 3 hexagonal crimps are made with a certified crimp tool to terminate safely.

Set Screw Torque Minimum is 10.5 Nm
Cable Jacket Strip Length is 5/16” (33mm)
For more information on terminations and assembly, view our Powersafe Assembly Guide.

Strain Relief
Different cable clamps are assembled onto the connector based on your cable size. The gland grips your cable to ensure an IP rating and secure connection of the connector.
We use 4 types of gland: M50, M40B, M40A and M40S (a bush is supplied for a M40SS gland)

  
    Cable
    Nominal Jacket OD (mm2)
    Cable Clamp
    Reduction Cable Clamp Bushing
  

    #4 SC
    12.07
    M40SS
    PP00575
  

    #2 SC
    13.21
    M40SS3
    PP00575
  

    #1 SC
    14.61
    M40SS
    PP00575
  

    1/0 SC
    15.24
    M40S
     PP00131
  

    2/0 SC
    16.38
    M40S
     PP00131
  

    3/0 SC
    18.16
    M40S
     PP00131
  

    4/0 SC
    19.43
    M40A
     N/A
  

Cable	Nominal Jacket OD (mm2)	Cable Clamp	Reduction Cable Clamp Bushing
#4 SC	12.07	M40SS	PP00575
#2 SC	13.21	M40SS3	PP00575
#1 SC	14.61	M40SS	PP00575
1/0 SC	15.24	M40S	PP00131
2/0 SC	16.38	M40S	PP00131
3/0 SC	18.16	M40S	PP00131
4/0 SC	19.43	M40A	N/A

  
    Cable
    Nominal Jacket OD (mm2)
    Cable Clamp
    Reduction Cable Clamp Bushing
  

    #4 Type W
    14.86
    M40SS3
    PP00575
  

    #2 Type W
    16.51
    M40S
    PP00131
  

    #1 Type W
    18.54
    M40S
    PP00131
  

    1/0 Type W
    19.05
    M40A
    N/A
  

    2/0 Type W
    20.96
    M40A
    N/A
  

    3/0 Type W
    23.11
    M40A
    N/A
  

    4/0 Type W
    24.38
    M40A
    N/A
  

    250 MCM
    25.91
    M40A
    N/A
  

Cable	Nominal Jacket OD (mm2)	Cable Clamp	Reduction Cable Clamp Bushing
#4 Type W	14.86	M40SS3	PP00575
#2 Type W	16.51	M40S	PP00131
#1 Type W	18.54	M40S	PP00131
1/0 Type W	19.05	M40A	N/A
2/0 Type W	20.96	M40A	N/A
3/0 Type W	23.11	M40A	N/A
4/0 Type W	24.38	M40A	N/A
250 MCM	25.91	M40A	N/A

  
    Cable
    Nominal Jacket OD (mm2)
    Cable Clamp
    Reduction Cable Clamp Bushing
  

    #4 DLO 2KV
    11.7
    M40SS
    PP00575
  

    #2 DLO 2KV
    13
    M40SS
    PP00575
  

    #1 DLO 2KV
    16.3
    M40S
    PP00131
  

    1/0 DLO 2KV
    17.8
    M40S
    PP00131
  

    2/0 DLO 2KV
    18.5
    M40S
    PP00131
  

    3/0 DLO 2KV
    20.3
    M40A
    N/A
  

    4/0 DLO 2KV
    21.3
    M40A
    N/A
  

    250 MCM
    23.9
    M40A
    N/A
  

    300 MCM
    25.3
    M50
    N/A
  

    350 MCM
    26.9
    M50
    N/A
  

    400 MCM
    28.2
    M50
    N/A
  

    500 MCM
    30.5
    M50
    N/A
  

Powersafe Configuration Guide

Use this guide to find out about everything Powersafe.

What are the types of Powersafe Connector?

Connector Gender Explained

Line Connector Configuration Help

Termination: How are Powersafe Connectors terminated?

View the Powersafe Assembly Guide >

Navigation

Contact Us

Address

Cable	Nominal Jacket OD (mm2)	Cable Clamp	Reduction Cable Clamp Bushing
#4 DLO 2KV	11.7	M40SS	PP00575
#2 DLO 2KV	13	M40SS	PP00575
#1 DLO 2KV	16.3	M40S	PP00131
1/0 DLO 2KV	17.8	M40S	PP00131
2/0 DLO 2KV	18.5	M40S	PP00131
3/0 DLO 2KV	20.3	M40A	N/A
4/0 DLO 2KV	21.3	M40A	N/A
250 MCM	23.9	M40A	N/A
300 MCM	25.3	M50	N/A
350 MCM	26.9	M50	N/A
400 MCM	28.2	M50	N/A
500 MCM	30.5	M50	N/A

Powersafe Configuration Guide

Use this guide to find out about everything Powersafe.

What are the types of Powersafe Connector?

Connector Gender Explained

Line Connector Configuration Help

Termination: How are Powersafe Connectors terminated?

View the Powersafe Assembly Guide >

Navigation

Contact Us

Address

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