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Powerline Connectors
Quality Checking
Objective:
This procedure identifies the recommended method of terminating a range of power cables to our Set Screw (or Pinch Screw) contacts
and our Crimp Contacts. It sets out in clear, easy to read and understand, step by step instructions, the preparation of the cable, the
termination method and the areas which need to be considered to ensure a correct and successful termination.
Safety:
In all assemblies where metal items are being assembled and in particular where cables are being processed, handling is very important.
Tooling such as cutters and sharp bladed knives must be handled with care. When conductor wires are cut it is recommended that Safety
Glasses should be worn. It is the operators responsibility to follow every safety instruction and if they are unsure on any aspect of the
assembly / termination, to seek information from a qualified person.
Initial Quality Checks:
Prior to use, all contacts and insulators should be checked as follows:
(a)
Ensure the band on the Male Contact is not broken or twisted and is positioned correctly in the groove.
(b)
Ensure the insulated nose of the Male Contact is not broken, cracked or discoloured.
(c)
Ensure the Insulated nose of the Female Contact is not broken, cracked or discoloured and can be fully recessed into the
metal body of the contact.
(d)
The 2 set screws supplied with the Set Screw contacts are a special dome fronted design. They are 16mm long and have a
5mm A/F drive. Other set screws are not recommended as they may cause damage to the contact / conductor termination.
(e)
Check for any signs of rust on the electrical contact and component parts.
(f)
Check for any cracks or breaks on the connector insulator.
(g)
Ensure the clip retainers inside each insulator are not discoloured or broken.
Selection of Cable Gland.
1)
Ensure the cable gland has a sealing o-ring and internal compression sleeve fitted.
2)
The cable gland must be positioned onto the cable prior to fitting the terminated
contact into the connector insulator.
3)
To ensure environmental sealing between the cable and connector, careful
consideration is required to select the correct gland for the external cable
diameter being used.
4)
We have 4 standard cable glands available as follows:
M40S.
External cable diameters from 15mm to 20mm.
M40M. External cable diameters from 20mm to 25mm.
M40OS. External cable diameters from 25mm to 32mm.
M50.
External cable diameters from 32mm to 37mm.
5)
Tighten the cable glands to a torque of 13Nm to ensure correct environmental
sealing is obtained.
The Set Screw Contact:
Below is a picture of the Male and Female contacts as supplied.
The Crimp Contact:
Below is a picture of both the Male and Female crimp contacts
as supplied. These can be supplied for termination to 185mm²,
240mm² and 300mm² stranded conductor applications. If
clarification on size is required, please consult the factory.
1
Switches Plus Components Pty Ltd
242 Governor Road, Braeside, VIC, 3195
Phone: 03 8587 3200
Email: sales@switchesplus.com.au
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Summary of Contents for Ten47 Powerline PSF-E-GN-T4-FP
- Page 1 Powerline Connectors Quality Checking Objective: This procedure identifies the recommended method of terminating a range of power cables to our Set Screw (or Pinch Screw) contacts and our Crimp Contacts. It sets out in clear, easy to read and understand, step by step instructions, the preparation of the cable, the termination method and the areas which need to be considered to ensure a correct and successful termination.
- Page 2 Powerline Connectors Cable Preparation Cable Selection and Preparation: Most power cables consist of multi-stranded conductors and double insulated Jackets. Our contacts are not designed to terminate onto solid conductors. Our Set Screw Contact range is from 25mm² to 120 / 150mm². (The internal dimensions of the set screw contact was originally designed for 120mm²...
- Page 3 Powerline Connectors Termination and Assembly Termination to Set Screw contacts: Select the cable and strip the Insulation / Jacket in accordance with Table 1. Slide Contact Removal Collar onto cable. Select the appropriate compression sleeves and fit onto the stripped cable end. Fully slide the sleeves and stripped cable into the rear of the contact and position collar correctly.
- Page 4 Powerline Connectors Checklist In conclusion and this can be used as a check list for build or maintenance, the following points need to be considered: Contact: Have the contacts been checked for any signs of damage? Have the appropriate reduction sleeves been supplied? Is the correct tooling available for the set screw and crimp contact terminations? On the maintenance schedule, does the contact show sign of rust due to water ingress? Cable Termination:...
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