Powersafe Configuration Guide

There are two primary 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 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.

Use the slider below to help you distinguish between the connector types.

There are 2 types of termination for Powersafe, Crimp and Set Screw.

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 25mm² – 300mm². Phase 3’s standard size is 120mm² and 240 mm², which for instance fits with standard sized HO7RNF power cable. We recommend 3 hexagonal crimps are made with a certified crimp tool to terminate safely.

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

• Set Screw Torque Minimum is 10.5 Nm
• Cable Jacket Strip Length is 33mm

For more information on terminations and assembly, view our Powersafe Assembly Guide.

Panel Mount are secured with an M12 threaded post termination. The standard connector is mounted to a panel through 4 fixing holes on the flange. As an alternative, flange holes can be fitted with M6 threaded inserts for either front or rear fixing. 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 (i.e lug) over the threaded area.
3. Refit the Washer and bolt on to the threaded area and tighten to a maximum of 12 – 14Nm.

For more information on terminations and assembly, view our Powersafe Assembly Guide.

Port Numbers Explained

The standard Powersafe Sequential Mating Box has 5 ports for three phase electricity (Earth, Neutral, Live 1, Live 2, Live 3). However, some electrical specifications do not require a neutral line, therefore we manufacture a 4 port box. Alternatively, you can use a 5 port box with a dummy connector to transform it into a 4 port box for temporary applications – please ask our Sales Manager.

Gender Explained

The Powersafe Box is available in both source and drain versions.

Source Boxes are usually the live end of the connection. The Source Powersafe Box accepts connection with Drain Connectors.

Drain Boxes are usually not live ends and receive the connection. The Drain Powersafe Box accepts connection with Source Connectors.

The mark of UL approval is granted by the Underwriters Laboratories company, an independent safety science organisation dedicated to promoting safe living and working environment. With over a century of expertise in innovating safety solutions, UL helps to safeguard people, products and places, whilst facilitating trade and providing buyers with peace of mind. You can find out more about UL certification and the tests that are carried out to gain certification, by visiting the UL website.

Phase 3’s Compliance Manager, Lee Corrigan, who led the project for UL approval said, “It’s been an enjoyable challenge gaining UL approval for myself and the team, who have worked extremely hard on this project. It’s great for the product to be recognised for its safety features and high quality. We feel this will help open many doors in the US and other markets for us as it’s now one of the highest rated single pole connectors with UL approval.”

UL Certification is usually required in the USA and Canada.