Powersafe Configuration Guide

Use this contents to find what you need to know within the Powersafe Configuration Guide:

Powersafe Explained

Types of Connectors
Connector Gender Explained

Line Connector Configuration Help

Cable Sizes and Cable Terminations Explained
Strain Relief Explained

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 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
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 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
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