Before you start
A poorly done crimp is one of the most common causes of failure in power connectors: overheating, high contact resistance, or, in the worst case, disconnection under load. The good news is that, with the right tool and following the official die chart, it is a repeatable and reliable process.
This guide applies to the entire Phase3 PowerSafe range, compatible with standard Powerlock® systems, for cable cross-sections from 25 mm² to 300 mm².
💡 Crimping must always be carried out by a qualified electrician, with the cable de-energized and following the instructions in this article together with the manufacturer’s manual.
Before crimping, you need two tools: one to strip the cable to the correct length, and another to crimp the contact with the right die.
- Cable stripper
Suited to the size range of your cable, so as not to damage the inner strands before crimping. - HT131-C manual crimping tool
Ideal for occasional use or one-off jobs on site, with interchangeable dies. - B131-C hydraulic crimping tool
For heavy workshop use: faster and more uniform crimping on large cross-sections. - Caliper or tape measure
To check the stripping length before inserting the cable into the contact.
Official crimping die chart
Each cable cross-section requires a specific die and number of crimp points. This is the official Phase3 table (Assembly Guide, Sept. 2022):
CABLE CROSS-SECTION
DIE
CRIMP POINTS
25 mm²
ME5
2 points
70 mm²
ME14
2 points
120 mm²
ME24
3 points
240 mm²
ME48
3 points
300 mm²
ME60
3 points
Step by step
- Strip the cable to the specified length
Use the stripper suited to your cable’s cross-section, without damaging the inner strands. - Insert the cable into the contact
Check that no strands are left sticking out of the contact before crimping. - Crimp with the matching die
Use the die from the table above according to the cable cross-section (for example, ME24 for 120 mm²). - Check the result visually
The crimp should be uniform, with no burrs or irregular deformation on the contact. - Fit the contact into the connector
Apply the specified tightening torque to the cable gland before considering the installation complete.
Tightening torque
For screw termination, the minimum tightening torque is 10.5 Nm. Closing the cable gland requires 11 Nm. Insufficient tightening can leave play in the contact; excessive tightening can damage the housing.
Common mistakes to avoid
- Using a die of a different size than the actual cable cross-section.
- Stripping the cable more or less than specified, leaving exposed copper or loose strands.
- Not checking the crimp before fitting the contact into the connector.
- Handling the connector while energized: it must always be done with no load.
- Not applying the correct tightening torque to the cable gland.
