Phase3 Powersafe User manual

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CONNECTORS USA
POWER CONNECTOR
ASSEMBLY GUIDE

1
Phase 3 Connectors USA
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Tel: [phone]
Phase 3 Connectors strive to make sure that customers are 100%
satisfied with our product. To do so we have written detailed procedures
to guide you through the steps of correctly assembling and maintaining
the product.
Due to the wide range of cable types available in today’s market, to
guarantee that an acceptable result is obtained when Powersafe
Connectors are terminated to cables, the process for the variety of
terminations has to be evaluated.
This procedure provides all the details of how to successfully terminate
powersafe connectors, either by crimping, set screws or threaded post
methods.
1. Overview
1. Overview
2. Termination Methods
2.1 Procedure for Set screw termination
2.2 Procedure for Panel Mounted Connectors
2.3 Crimp Termination
3. Safety and maintenance checks
Contents
The recommended assembly methods are detailed in the pages to
follow.
If in doubt please contact Phase 3 Connectors USA.
This Procedure tells you:
zHow to perform a set screw termination
zHow terminate a threaded post panel type connector
zThe recommended crimp tools and dies
zHow to perform a crimped termination
zSafety checks
2. Termination Methods
There are three methods on how to terminate cables on the Powersafe contacts: Set Screw
termination (page 2), Threaded Post termination (page 3) and Crimp termination (page 4).

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2.1. Set Screw Termination Procedure
The recommended assembly procedure has been devised to show step-by-
step how to terminate cables to our set screw contact. For a satisfactory
termination it is essential that the recommended assembly procedure is used.
1. From the packaging: Remove the cable gland from the
insulator and remove the contact.
2. Check the cable overall diameter. The standard Black M40A
gland will facilitate cable diameter of .75-1.1" (19-28mm).
If your cable is of a diameter between .59-.71" (15-18mm)
diameter, the PP00131 reduction bush supplied should be
fitted to the M40A cable gland. To do this, remove the black
rubber sealing ring inside the rear of the gland and replace
with the PP00131 M40S bush (*see tables 1 and 1a).
3. Slide the completed cable gland along the cable jacket.
4. With care, strip back the cable insulation 1.25" (33mm). Try
not to damage any of the conductor’s stranding.
5. Fit the correct end sleeve or
combination of end sleeves (see table
below) over the conductor strands. Take
care to ensure all the wire strands are
inside the end sleeve.
Set Screw End Sleeve Selection Guide & Wire Guage Assembly Chart (N.American) (Table 1)
WIRE
AWG
AVERAGE
CONDUCTOR
OD
(INCHES)
NOMINAL
CONDUCTOR
SIZE RANGE
(INCHES)
REDUCTION
SLEEVE KIT
REDUCTION
SLEEVE KIT
PART #
ACCEPTABLE
JACKET
RANGE OD
(INCHES)
CABLE
CLAMP
REDUCTION
CABLE
BUSHING
PART #
40.23 .22 - .26 R25 PP00015 .39 - .63 M40SS PP00575
20.29 .27 - .31 R35 PP00016 .39 - .63 M40SS PP00575
10.33 .33 - .37 R50 PP00017 .39 - .63 M40SS PP00575
1/0 0.37 .33 - .37 R50 PP00017 .59 - .90 M40S PP00131
2/0 0.42 .39 - .43 R70 PP00018 .59 - .90 M40S PP00131
3/0 0.47 .46 - .5 R95 PP00006 .59 - .90 M40S PP00131
4/0 0.53 .52 - .54 R120 STD .75 - 1.1 M40A STD
250MCM 0.58 .52 - .56 R120 STD .75 - 1.1 M40A STD
Using the table above (See next page for European measurements), select the appropriate reduction sleeves
and slide in sequence on to the exposed conductor stranding. Please note; all sleeves down to the size
recommended for the cable in use must be used.
i.e. For a #2 (35mm2) cable, the R120, R95, R70, R50 and R35 sleeves should all be used in sequence. All the
sleeves fit perfectly inside each other to create a gradual reduction span. The flared end of the sleeves should
be against the cable insulation.

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Set Screw End Sleeve Selection Guide & Wire Guage Assembly Chart (European) (Table 1a)
CSA
MM2
AVERAGE
CONDUCTOR
OD (MM)
NOMINAL
CONDUCTOR
SIZE RANGE
(MM)
REDUCTION
SLEEVE KIT
REDUCTION
SLEEVE KIT
PART #
ACCEPTABLE
JACKET
RANGE OD
(MM)
CABLE
CLAMP
REDUCTION
CABLE
BUSHING
PART #
25 6.5 5.7 - 6.7 R25 PP00015 10 - 16 M40SS PP00575
35 7.4 6.9 - 7.9 R35 PP00016 10 - 16 M40SS PP00575
50 8.9 8.4 - 9.4 R50 PP00017 15 - 23 M40SS PP00575
70 10.5 10 - 11 R50 PP00018 15 - 23 M40S PP00131
95 12.2 11.7 - 12.7 R70 PP00006 15 - 23 M40S PP00131
120 13.8 13.3 - 14.3 R95 STD 19 - 28 M40A STD
Dowel pins are designed to be used only once. In the event that the connector is unassembled a new
dowel pin should be fitted on re-assembly.
Also, never use a dowel pin that is not a tight interference fit within the Insulator as this could lead to
failure of the watertight barrier or allow the contact to dislodge from the insulator.
Periodic checks should be made to ensure security of dowel pins.
9. Now screw the cable gland onto the insulator and tighten the body and dome nut to 97 in/lbs.
Your connector should now be complete and ready for an overall inspection.
7. Now insert the contact into the rear of the
insulator and align the hole in the contact so
that it is in line with the holes in the insulator.
8. Now align the dowel pin with the tapered end first with the hole in the insulator. The dowel
pin is designed to be a tight interference fit with insulator hole and it is necessary to drive
the pin using a hammer through the insulator and contact. When fully inserted the pin will be
flush with the surface of the insulator body.
6. Slide the cable and reduction sleeves into the back of the contact ensuring they are fully
inserted inside the contact. Using a 5mm Allen bit, tighten the set screws 93 in/lbs.

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2.2 Panel Mounted Connectors Procedure
Panel connectors are supplied fully assembled and ready for direct
mounting to equipment.
1. When the panel Connector is mounted in
equipment: remove the nut and washer from the
threaded post section.
2. Fit your selected terminal or accessory over the
threaded area.
3. Refit the Washer and bolt on to the threaded area
and tighten to a MAXIMUM of 106 - 124 in/lbs.
2.3 Crimp Termination
It is important to use the recommended Crimp
tool and Die to ensure a satisfactory crimp.
Tools Required:
zME series Crimp Die
zHand Held Crimping Tool: HT 131-C
zCordless Hydraulic 14.4v Crimping
• Tool: B 131-C
A hydraulic crimping tool and hexagonal Die set is used to perform a crimp termination.
Selection of the correct crimp die is essential to achieve a reliable result.
As cable conductor sections vary widely, the table below is intended as a guide to appropriate die selection.
Cable tensile test should be performed to ensure the final crimp termination meets the tensile and mv drop
test of a particular specification.
The assembly of the Insulator and Glands is the same as previously described for the set
screw terminations (page 2).
1. Select the appropriate Die set from Table 2/Table 2a (page5/6),
(For example if you are using a 500MCM (240mm2) cable use Die set
ME48).
2. Strip the cable jacket to leave 1.75" (43mm) of conductor exposed.
3. Slide the conductor into the rear of the contact. Take care to ensure
all the wire strands are inside the contact.
Continues on Page 7.

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CONTACT
RATING
CONTACT
SIZE
CONTACT
INNER
DIAMETER
(INCHES)
NOMINAL
CONDUCTOR
SIZE RANGE
(INCHES)
WIRE AWG
AVERAGE
CONDUCTOR
OD (INCHES)
WIRE
AMPACITY
RATING
ACCEPTABLE
JACKET
RANGE OD
(INCHES)
CABLE
CLAMP
REDUCTION
CABLE
BUSHING
PART #
TENSILE
STRENGTH
IEC61238-1
(IN/LBS)
DIE SET
CODE &
(NO. OF
CRIMPS)
UP TO
500A
C25 TBD .22 - .26 40.23 140A .39 - .63 M40SS PP00575 13.25 ME 05 (2)
C35 0.37 .27 - .31 20.29 190A .39 - .63 M40SS PP00575 18.5 ME 07 (2)
C50 0.39 .33 - .37 10.33 220A .39 - .63 M40SS PP00575 26.5 ME 10 (2)
C50 0.39 .33 - .37 1/0 0.37 260A .59 - .90 M40S PP00131 26.5 ME 10 (2)
C70 0.45 .39 - .43 2/0 0.42 300A .59 - .90 M40S PP00131 37 ME 14 (2)
C95 0.53 .46 - .5 3/0 0.47 350A .59 - .90 M40S PP00131 50.5 ME 19 (2)
C107 0.57 .52 - .54 4/0 0.53 405A .75 - 1.1 M40A STD 50.5 ME 19 (2)
C120 0.6 .52 - .56 250MCM 0.58 455A .75 - 1.1 M40A STD 63.75 ME 24 (2)
UP TO
800A
C150 0.67 .59 - .63 300MCM 0.63 505A .75 - 1.1 M40A STD 79.5 ME 30 (2)
C185 0.76 .65 - .69 350MCM 0.68 570A .87 - 1.26 M40B STD 98.25 ME 37 (2)
C240 0.83 .75 - .79 500MCM 0.81 700A .87 - 1.26 M40B STD 127.5 ME 48 (3)
C300 1.85 - .89 600MCM 0.89 780A .87 - 1.26 M40B STD 159.25 ME 60 (3)
Single Conductor Crimp Contact & Wire Guage Assembly Chart (N.American) (Table 2)

6
Phase 3 Connectors USA
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CONTACT
RATING
CONTACT
SIZE
CONTACT
INNER
DIAMETER
(MM)
NOMINAL
CONDUCTOR
SIZE RANGE
(MM)
CSA MM2
AVERAGE
CONDUCTOR
OD (MM)
WIRE
AMPACITY
RATING
ACCEPTABLE
JACKET
RANGE OD
(MM)
CABLE
CLAMP
REDUCTION
CABLE
BUSHING
PART #
TENSILE
STRENGTH
IEC61238-1
(N/M)
DIE SET
CODE &
(NO. OF
CRIMPS)
UP TO
500A
C25 TBD 5.7 - 6.7 25 6.2 136A 10 - 16 M40SS PP00575 1.5 ME 05 (2)
C35 9.5 6.9 - 7.9 35 7.4 200A 10 - 16 M40SS PP00575 2.1 ME 07 (2)
C50 10 8.4 - 9.4 50 8.9 250A 15 - 23 M40SS PP00575 3ME 10 (2)
C70 11.5 10 - 11 70 10.5 310A 15 - 23 M40S PP00131 4.2 ME 14 (2)
C95 13.5 11.7 - 12.7 95 12.2 369A 15 - 23 M40S PP00131 5.7 ME 19 (2)
C107 14.5 13.1 - 13.6 107 13.1 380A 15 - 23 M40A STD 5.7 ME 19 (2)
C120 15.2 13.3 - 14.3 120 13.8 432A 19 - 28 M40A STD 7.2 ME 24 (2)
UP TO
800A
C150 16.95 14.9 - 15.9 150 15.4 497A 19 - 28 M40A STD 9ME 30 (2)
C185 19.2 16.4 - 17.4 185 16.9 564A 22 - 32 M40B STD 11.1 ME 37 (2)
C240 21 19 - 20 240 19.5 673A 22 - 32 M40B STD 14.4 ME 48 (3)
C300 25.4 21.5 - 22.5 300 22 773A 22 - 32 M40B STD 18 ME 60 (3)
Single Conductor Crimp Contact & Wire Guage Assembly Chart (European) (Table 2a)

7
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4. Place the contact and cable carefully into the die set and close the crimping tool. In the
case of tool HT131 the tool hands are pumped until they go no further. As the tool reaches the
required compression you will feel and hear a click. The tool can then be opened to release the
finished crimp.
5. In some case more than one crimp is recommended to ensure the maximum surface are
of crimp are achieved. From table 2 we can see for example that a 500MCM (240mm2) crimp
should be made in 3 equidistant positions along the contact crimp area.
Crimp 1 Crimp 2 Crimp 3
3. Safety and Maintenance Checks
a) Check external surface of Insulators
periodically for signs of cracks or breaks.
If there are any signs of damage, then
the insulator should be replaced.
b) Check cable glands for tightness.
In use, cable glands can become loose
and this could lead to water ingress, so
periodic checking is essential.
c) Check condition and position of Cable
gland seal within the cable gland. If any
degradation is suspected a new seal or
gland should be fitted.
d) With Drain connectors: check
condition of the front O ring for signs of
degradation. Also periodically a film of
Silicone grease should be applied to the
O ring surface. This will allow continued
ease of mating and protect the O ring.
e) With Drain connectors: check the
secondary locking pin which is spring
loaded moves freely. It should travel fully
down to the insulator surface and fully
extend.
f) Check security and position of dowel
pins. With a slight tap with a hammer
the dowel pins should not move.
Following these steps above will ensure the long term safety and
continued performance of your connectors.
** Replacement parts for service are readily available from the factory

WARNING!
Do not alter this product in any way. Doing so may lead to serious injury or death. Use copper
conductors only. Read Instructions completely before wiring. Ensure all safety checks are
carried out before and after use. This product should be installed, Inspected and maintained
by qualified electricians only, in accordance with local and national electrical codes.
DID YOU KNOW
Phase 3 manufactures Sequential Mating
Boxes for power distribution in the Powersafe
range. Ask your sales rep
To the best of our knowledge, the information is correct at the time of printing. However, we cannot be held responsible for any errors made,
or changes to the specification as part of ongoing refinements to our product range. E&OE. The rights and ownership of all trademarks are
recognized.
Phase 3 Connectors HQ
Unit 9 Coopers Point
Coopers Lane,
Knowsley, L33 7UB
Phase 3 USA
2A John Walsh Boulevard
Peekskill, NY 10566
833-738-7285
[email protected]
CONNECTORS USA