5 Best Methods for Installing POWERSAFE (POWERLOCK) Connectors

5 Best Methods for Installing POWERSAFE (POWERLOCK) Connectors Step by Step

Are you looking for reliable and effective methods for installing power connectors? Phase 3 Connectors has provided a detailed guide describing step by step the three most common methods: bolting, threaded stud installation, and crimping tools. In this article, we will look at the first two methods, discussing their key steps and recommendations.

Bolting Method for POWERSAFE (POWERLOCK) Connectors

The bolting method is one of the most commonly used techniques for installing power connectors. Here are the steps you need to follow to properly terminate a cable using this method:

Step 1: Preparation

• Unpack the product and remove the cable sleeve and contact.
• Check the cable diameter. The standard black M40A sleeve is designed for cables with a diameter of 19–28 mm. If the cable is between 15 and 18 mm, apply the PP00131 reducer to the M40A sleeve.

Step 2: Cable Preparation

• Slide the cable sleeve along the cable sheath.
• Use the appropriate end ferrule or combination of ferrules on the wires. Ensure that all wire strands are inside the end ferrule.

Step 3: Cable Termination

• Carefully remove 33 mm of cable insulation. Try not to damage any wire strands.

Step 4: Bolting

• Insert the cable and reducers into the rear of the contact, ensuring they are fully seated inside the contact. Using a 5 mm wrench, tighten the screws according to the table.

Threaded Stud Installation Method for POWERSAFE (POWERLOCK) Connectors

Another popular method for installing power connectors is the threaded stud installation. Here is how to complete it step by step:

Step 1: Inserting the Contact

• Insert the contact into the rear of the insulator and align the hole in the contact with the holes in the insulator.

Step 2: Installing the Threaded Stud

• When the panel connector is mounted in the device, remove the nut and washer from the threaded section.
• Place the selected terminal or accessory onto the threaded area.
• Reinstall the washer and nut, tightening to a maximum of 12–14 Nm.

With these detailed instructions, installing power connectors becomes simple and effective. Now let's move on to the next section, where we will discuss crimping methods step by step and final connector assembly.

Pin Crimping Method

The last method we will discuss is the crimping method, which requires special tools for proper installation. Here is how to proceed:

Step 1: Tool Preparation

• Ensure you have the proper crimping tools, including the appropriate jaw set.

Step 2: Selecting the Crimping Set

• Select the correct crimping set based on the cable size. For example, if you are using a 240 mm² cable, use the ME48 set.

Step 3: Cable Preparation

• Strip the cable insulation, leaving 43 mm of exposed conductors.

Step 4: Inserting the Conductor

• Insert the conductor into the rear of the contact, ensuring all strands are inside the contact.

Step 5: Crimping

• Carefully place the contact and cable into the crimping tool and close the tool. When it reaches the correct compression, you will feel and hear a click. Then the tool can be opened to release the crimped contact.

When choosing the appropriate installation method, always follow the manufacturer’s recommendations and adhere to the steps precisely. Let's now move on to final connector assembly and the discussion of safety and maintenance procedures.

Clamping Method

The clamping method involves mechanically clamping the conductors using special clamps, ensuring a solid electrical connection. Here are the steps for installing the connector using this method: Step 1: Conductor Preparation

• Properly prepare the conductor by removing insulation to the specified length and bending a small section of the conductor end at a 90-degree angle. Step 2: Inserting the Conductor into the Connector
• Insert the appropriate cable end into the clamp connector, ensuring all conductor strands are properly positioned.
• Use a special clamping tool to securely clamp the connector onto the conductor. Make sure the clamping force is sufficient to guarantee a reliable connection.

Soldering Method for POWERSAFE (POWERLOCK) Connectors

The soldering method involves joining conductors by melting solder and bonding it to the connector components. Here are the steps for installing a connector using this method: Step 1: Conductor Preparation

• Remove insulation from the conductor to the specified length and clean the exposed section using a cleaning agent or sandpaper.
• Apply solder to the cleaned area of the conductor and the appropriate part of the connector.
• Insert the cleaned conductor into the connector and melt the solder using a soldering iron to ensure a solid connection.

Final Connector Assembly and Safety Procedures

Proper termination of power connectors is crucial for ensuring a reliable electrical connection. After completing the installation, it is important to perform safety and maintenance procedures to ensure long-term performance and safety.

Safety Procedures:

1. Regular Insulator Inspections: Periodically check the outer surface of insulators for cracks or damage. If any damage is detected, the insulator must be replaced.

2. Checking Cable Gland Tightness: During operation, cable glands may loosen, allowing water to enter. Regularly checking their tightness is therefore essential.

3. Inspecting O-ring Condition: If you suspect degradation of the O-ring seals, they should be replaced. Seals must be in good condition and properly positioned inside the connectors.

4. Regularly check the condition of the front sealing ring. Additionally, applying a thin layer of silicone grease to the sealing ring surface will ease mating and protect the ring from degradation.

Performing these procedures after installing power connectors is essential to ensure long-term performance and safety. They help prevent potential failures and hazards in the electrical system.

If needed, replacement service parts are readily available from the manufacturer. It is also important to remember that all work related to installation, inspection, and maintenance of power connectors should be carried out only by qualified electricians, in accordance with local and national electrical regulations.

Summary

Installing POWERSAFE (POWERLOCK) connectors requires precision and the right tools, as well as strict adherence to the manufacturer’s recommendations. With detailed instructions, you can successfully assemble cables, ensuring reliable and safe connections.

Also read:
How to Safely Connect POWERSAFE (POWERLOCK) Connectors
How POWERLOCK Connectors Work – Key Information