PowerSyntax
Tested Quality
We choose independent labs to vouch for our products
PowerSyntax
Tested Quality
We choose independent labs to vouch for our products
Assessing the qualities and features of all products and testing them. This is our philosophy.
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Compliance to standards
is not enough for usCompliance to standards
is not enough for usWe want to know our products' real potential in every condition
We want to know our products' real potential in every condition
Rather than being our target, compliance to standards’ prescriptions is just the starting point for us. Excellence, rather than compliance, is what we have pursued since we started the designing of our powerlock-style compatible PowerSyntax connectors. Our goal was to set a new benchmark on this type of single-pole connector, with unprecedented levels of safety, reliability and sturdiness.The result is an innovative connector where nothing has been left to chance.
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The importance of a solid testing policy
The importance of a solid testing policy
Proven performances means proven safety for operators
Proven performances means proven safety for operators
To make sure our PowerSyntax single-pole connectors complied with regulations and met international standards, we tasked independent testing agencies to guarantee the integrity of the testing conditions as well as data and absolute transparency on results. With full safety for operators, equipment and working environment as our priority, all phases of the production cycle focus on achieving uncompromised reliability, from the design stage to the choice of the best materials and the state-of-the-art manufacturing, to thorough testing with simpler examinations carried out internally at the company, and more complex external tests carried out by third party laboratories certifying that the standard-exceeding performances we had in mind have been achieved.
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Truly waterproof when they mate
Truly waterproof when they mate
IPX7 proven by temporary immersion test
IPX7 proven by temporary immersion test
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Temporary outdoors power connections are exposed to all possible weather conditions, with the risk that the connectors are used in the rain and puddles may form in working environments. So, single-pole connectors must be protected against the ingress of liquids. Are PowerSyntax connectors truly IPX7 when mated? To verify their IP rating in accordance with IEC 60529, a pair of PowerSyntax mated connectors have been tested by immersing them in water for thirty minutes, at a depth between 0.15 m and 1 m. Once pulled out of the container, water ingress was checked on the source and drain connectors, both at each cable gland side and the drain-to-source connection area. All three testing points were dry and fully compliant with IPX7 waterproof rating.
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Don't be afraid to be rough
Don't be afraid to be rough
IK10 proven by impact resistance test
IK10 proven by impact resistance test
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Power connectors may be used in many different situations and environments where chances are likely they will be mechanically stressed and will have to withstand heavy impacts. For the IK10 impact resistance test, the connector was fixed on a rigid support, and the impact energy of a 5 kg free falling steel ball has been applied three times on the same target point from a height of 0.408 m. The test results show that the PowerSyntax connectors are highly impact-resistant, in compliance with IK10 rating according to IEC 62262 IK code (which regulates testing procedure for mechanical impacts on all the electrical enclosure surfaces).
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Never get overheated, even under stress
Never get overheated,
even under stressOur temperature results are certified by independent test labs
Our temperature results are certified by independent test labs
PowerSyntax connectors have been tested by third party agencies to measure and verify their temperature rise at determined load current values.
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Temperature test set up basics
Temperature test set up basics
The temperature tests were carried out on a mated pair of Line Drain / Line Source single pole PowerSyntax SPX4 connectors (rated for currents up to 480 amp), each one wired on single core flex 120 mm² type H07RN-F copper cable, with measurements at increasing current values, from common operating currents of 250 and 400 amp, up to the connectors’ nominal value of 480 amp, and even to an off-scale value of 550 amp, simulating an extreme condition that could only occur if they were to be used improperly by mistake. Test results are shown in the charts below.
measuring point description T1 Cable temperature of the source near retention screw T2 Temperature of the source contact on the retention point termination T3 Temperature of the drain contact on the retention point termination T4 Cable temperature of the drain near retention screw T5 Housing of connector -
250 amp
250 amp
Recorded
temperaturesRecorded
temperaturespoint T (°C) T1 47,0 T2 47,9 T3 47,2 T4 46.4 T5 38,0 -
400 amp
400 amp
Recorded
temperaturesRecorded
temperaturespoint T (°C) T1 87,1 T2 89,1 T3 87,2 T4 85,2 T5 62,9 -
480 amp
480 amp
Recorded
temperaturesRecorded
temperaturespoint T (°C) T1 113,9 T2 116,8 T3 114,5 T4 111,7 T5 77,4 -
550 amp
550 amp
Recorded
temperaturesRecorded
temperaturespoint T (°C) T1 146,6 T2 150,5 T3 147,1 T4 143,3 T5 93,6 -
A flawless connection
with low resistanceA flawless connection
with low resistanceLow voltage drop values prevent excessive heat
Low voltage drop values prevent excessive heat
As well as for temperature rise, PowerSyntax connectors have also been tested to measure and verify the voltage drop of the connectors at determined load current values, with the results showing extremely low resistance values.
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Voltage drop test set up
Voltage drop test set up
The voltage drop test was carried out in the same environment as the temperature rise test described previously. We submitted a mating pair of Line Drain / Line Source single pole PowerSyntax SPX4 connectors (rated for currents up to 480 amp), each one wired on single core flex 120 mm² type H07RN-F copper cable, with measurements at increasing current values, from common operating currents of 250 and 400 amp, up to the connectors’ nominal value of 480 amp, and even to an off-scale value of 550 amp, simulating an extreme condition that could only occur if they were to be used improperly by mistake. Test results are shown in the charts below.
measuring point description U1 Source point near retention screw U2 Source contact on the retention point termination U3 Drain contact on the retention point termination U4 Drain point near retention screw -
250 amp
250 amp
Recorded
voltage dropRecorded
voltage droppoint I(A) U (mV) R(mΩ) U4-U3 253,55 n/a n/a U3-U2 253.55 21,281 0,084 U2-U1 253.55 3,202 0,013 U4-U1 253,55 25,858 0,102 -
400 amp
400 amp
Recorded
voltage dropRecorded
voltage droppoint I(A) U (mV) R(mΩ) U4-U3 402.62 n/a n/a U3-U2 402.62 35,178 0,087 U2-U1 402.62 5,299 0,013 U4-U1 402.62 42,716 0,106 -
480 amp
480 amp
Recorded
voltage dropRecorded
voltage droppoint I(A) U (mV) R(mΩ) U4-U3 480,68 n/a n/a U3-U2 480,68 43,166 0,090 U2-U1 480,68 6,450 0,013 U4-U1 480,68 52,699 0,110 -
550 amp
550 amp
Recorded
voltage dropRecorded
voltage droppoint I(A) U (mV) R(mΩ) U4-U3 556.04 5,680 0,010 U3-U2 556.04 51,243 0,092 U2-U1 556.04 7,596 0,014 U4-U1 556.04 61,839 0,111 -
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What's the frequency?
What's the frequency?
Safety and high performances even in unusual conditions
Safety and high performances even in unusual conditions
When referring to power connectors, the most common frequency might be 50 Hz in most cases. However in industrial sectors such as renewable energy plants or others, higher frequencies are routine. Then, what most times is defined as “exceptional” becomes "standard". When a customer asked us that the PowerSyntax connectors’ performances were tested for specific working conditions with a frequency of 120 Hz, we commissioned independent tests on our PowerSyntax to be carried out by an accredited specialized laboratory, to prove and certify their performances when those specific parameters were applied.
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Every single drop counts
Every single drop counts
Temperature test and voltage drop test results at 120 Hz frequency
Temperature test and voltage drop test results at 120 Hz frequency
The increase in frequency produces the so called "skin effect" and associated risks of increased voltage drop and temperature rise. In all electricity-related industrial sectors, every "drop" counts. It was crucial to prove how our connectors would behave in the specific, higher-frequency conditions. We commissioned an independent lab to carry out specific tests replicating the conditions that our customer had as their requirement. A mating pair of connectors composed of a PowerSyntax 750A Panel Source and a PowerSyntax oversized Line Drain 750A connector with a ComLug XL contact wired on 185 mm² copper cable, was powered with 500A current at 120 Hz. Test results are shown in the charts below.
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Recorded temperatures
Recorded temperatures
point description T (°C) point description T (°C) T1 Cable source 66,4 | T5 Plastic brown drain 48,3 T2 Connection source 66,4 | T6 Connection drain 70,3 T3 Brown shell source 66,4 | T7 Black shell drain 48,0 T4 Lamella source 57,4 | T8 Cable drain 64,4
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Recorded voltage drop
Recorded voltage drop
Measuring time at initial test at the end of the test Voltage drop 0.041148 0.041578 Current (A) 509,42 508,34 Impedance (mΩ) 0,0877 0.08179 -
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What is the skin effect?
What is the skin effect?
Skin effect is the tendency of an alternating electric current (AC) to become distributed within a cable such that the current density is largest near the surface and decreases exponentially with greater depths in the conductor. The electric current flows mainly at the "skin" of the cable, between the outer surface and a level called “skin depth”. Skin depth depends on the frequency of the alternating current. As frequency increases, current flow moves to the surface. At high frequencies the skin depth becomes much smaller. Skin effect reduces the effective cross-section of the conductor and thus increases its overall resistance.
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Built to be highly insulated
Built to be highly insulated
Dielectric test at 5000 V confirms the quality of PowerSyntax protective shells
Dielectric test at 5000 V confirms the quality of PowerSyntax protective shells
The most common voltage rating values for powerlock-style connectors are 1000 V AC / 1500 V DC. When a customer asked us that the dielectric qualities of the PowerSyntax outer shells were tested in specific working conditions with a voltage of 5000 V, we commissioned independent tests on our PowerSyntax to be carried out by an accredited specialized laboratory, to prove and certify the dielectric performances of our connectors when those specific parameters were applied. The dielectric test was performed subjecting the mated PowerSyntax connectors to a voltage greatly exceeding the operating voltage value. The test result proves that the protective shells can withstand the required operating voltage as no disruptive discharge or arcing were recorded, in full accordance with the acceptance criteria.
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A voltage of 5000 V has been applied for 60" to a mated pair of PowerSyntax 750A connectors and their thermoplastic shells to detect any leakage or improper passage through the protective part. During the test no disruptive discharges or arcing were recorded.
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Tailored testing on your behalf
Tailored testing on your behalf
Together we can do better and better
Together we can do better and better
Listening to our customers’ needs is essential for us. It is our customers’ feedback that has allowed continuous enhancements on our products. Our connectors today are widely considered a benchmark as regards safety, reliability and innovative features thanks to state of the art technology. However we are not going to stop here, as constant improvement is our goal. Our growth goes hand in hand with our customers’ growth. If you are going to use the connectors in a working environment with particular operating conditions, where specific performances are demanded, we will be ready to task independent laboratories to test the PowerSyntax according to your requirements.
