PowerFit 400A Single-Pole Power Connectors
PowerFit 400A single-pole power connectors bring IP67-sealed performance to high-current temporary and semi-permanent power distribution. Rated at 400A continuous with 120mm² cable (scalable to 660A with 240mm² cable) at up to 1000V AC / 1500V DC, the PowerFit system is engineered for environments where weather, dust, and rough handling are everyday realities. Silver-plated brass contacts achieve 0.1 milliohm contact resistance. The push-and-twist connection mechanism with patent key-release pin locks securely under vibration and cable tension while allowing intentional, tool-free disconnection. Available in 8 housing colors with phase-encoded SKUs to prevent cross-convention wiring errors. TÜV Rheinland certified (ID 1111303479), CE marked, RoHS and REACH compliant. Compatible with major brands of single-pole power connector.*
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Understanding Source and Drain
PowerFit uses Source and Drain to describe connector roles, not "male" and "female." Understanding this terminology is essential for correct system wiring.
Electric direction: Panel Source → Line Drain ↔ Line Source → Panel Drain
Term | Contact Type | Key Feature | Mating Rule |
|---|---|---|---|
Source | Male contact (pin) | Patent key-release pin for intentional, tool-free disconnection | Panel Source mates with Line Drain. Line Source mates with Line Drain. |
Drain | Female contact (socket) | Silicone O-ring for IP67 sealing when mated | Panel Drain mates with Line Source. Line Drain mates with Line Source. |
Simple rule: Source always connects to Drain. Key-release pin (Source only) allows controlled disconnection. De-energize before mating or unmating.
Find Your Configuration
PowerFit 400A connectors are available in four configurations. Line connectors mount on cable with an ergonomic rubber grip and M40 cable gland. Panel connectors mount through a 42 × 42mm cutout with an M12 threaded post. All configurations are available in all 8 housing colors across 13 phase-specific SKU codes.
Configuration | Use When… | SKU Prefix | Connection | Contact |
|---|---|---|---|---|
Line Source | Inline cable connection where you need the key-release pin for controlled disconnection | PFLS-{color}-S120M40A | Push-and-twist + key-release | Male (pin) |
Line Drain | Inline cable connection on the receiving end, with silicone O-ring for IP67 sealing | PFLD-{color}-S120M40A | Push-and-twist | Female (socket) |
Panel Mount Source | Permanent panel or enclosure mount with key-release pin, M12 threaded post | PFPS-{color} | Push-and-twist + key-release | Male (pin) |
Panel Mount Drain | Permanent panel or enclosure mount with O-ring seal, M12 threaded post | PFPD-{color} | Push-and-twist | Female (socket) |
Line connectors carry the suffix -S120M40A (set screw, 120mm² cable, M40 gland, A-range bushing). Panel connectors have no suffix after the color code.
Phase-Encoded Color System
PowerFit is available in 8 housing colors with phase-encoded SKUs to prevent cross-convention wiring errors. The same physical color can represent different phases in different regional standards. The SKU prefix (1BK vs 2BK vs NBK) makes the electrical assignment unambiguous.
Phase | Color | Code | Convention | Line Drain SKU | Panel Source SKU | Browse |
|---|---|---|---|---|---|---|
Phase A (L1) — 3 Regional Colors | ||||||
L1 | Black | 1BK | North America (NEC) | PFLD-1BK-S120M40A | PFPS-1BK | |
L1 | Red | 1R | Australia | PFLD-1R-S120M40A | PFPS-1R | |
L1 | Brown | 1BN | Europe / IEC 60446 | PFLD-1BN-S120M40A | PFPS-1BN | |
Phase B (L2) — 4 Regional Colors | ||||||
L2 | Black | 2BK | Europe / IEC 60446 | PFLD-2BK-S120M40A | PFPS-2BK | |
L2 | Red | 2R | North America (NEC) | PFLD-2R-S120M40A | PFPS-2R | |
L2 | White | 2W | Australia | PFLD-2W-S120M40A | PFPS-2W | |
L2 | Yellow | 2Y | UK Old (pre-2004) | PFLD-2Y-S120M40A | PFPS-2Y | |
Phase C (L3) — 2 Regional Colors | ||||||
L3 | Blue | 3BL | NEC, Australia, UK Old | PFLD-3BL-S120M40A | PFPS-3BL | |
L3 | Grey | 3GY | Europe / IEC 60446 | PFLD-3GY-S120M40A | PFPS-3GY | |
Neutral (N) — 3 Regional Colors | ||||||
N | Black | NBK | Australia / UK Old | PFLD-NBK-S120M40A | PFPS-NBK | |
N | Blue | NBL | Europe / IEC 60446 | PFLD-NBL-S120M40A | PFPS-NBL | |
N | White | NW | North America (NEC) | PFLD-NW-S120M40A | PFPS-NW | |
Ground / Earth (PE) — Universal | ||||||
PE | Green | EGN | Universal (all regions) | PFLD-EGN-S120M40A | PFPS-EGN | |
Why phase-encoded SKUs matter: Black appears as 1BK (Phase A in North America), 2BK (Phase B in Europe), and NBK (Neutral in Australia). Ordering by phase code instead of color alone prevents dangerous cross-convention wiring errors. *Verify specific brand compatibility with KUPO before mixing connector brands.
International Phase Color Convention
Select the connector color that matches the phase convention for your region and system voltage.
Region | L1 | L2 | L3 | N | Ground |
|---|---|---|---|---|---|
NA 120/208V 1 | Green / G-Y | ||||
NA 277/480V 2 | Green / G-Y | ||||
IEC 60446 3 | Green-Yellow | ||||
AU/NZ Legacy 4 | Green-Yellow | ||||
China 5 | Green-Yellow |
1 North America 120/208V (NEMA / NEC) 2 North America 277/480V (NEMA / NEC) 3 Europe, UK, Australia (current IEC 60446)
4 Australia / New Zealand legacy (pre-IEC) 5 China (GB 50303) G-Y = Green-Yellow (earth/ground)
Built for Demanding Environments
Feature | Why It Matters in the Field |
|---|---|
IP67 sealed when mated | Complete protection against dust ingress and temporary water immersion (up to 1 meter, 30 minutes). Deploy in rain, mud, wash-down areas, and coastal environments without additional weatherproofing. The silicone O-ring on Drain connectors creates the waterproof seal. |
Silver-plated brass contacts | 0.1 milliohm contact resistance, significantly lower than plain brass. Reduces resistive heating at sustained high-current loads, extending contact life and improving efficiency across the full 400A/660A range. |
Push-and-twist with patent key-release pin | Secure mechanical lock that requires intentional action to disconnect. The key-release pin on Source connectors can be operated tool-free, or with a small slotted screwdriver. No accidental disconnection under vibration or cable tension. |
UL94-V0 flame rating | Highest vertical flame classification for plastics. Housing self-extinguishes within 10 seconds with no flaming drips. Superior to the HB rating found on many traditional single-pole connectors. |
Dual amperage: 400A / 660A | 400A continuous with standard 120mm² cable, scalable to 660A with 240mm² cable. One connector family covers two amperage tiers, reducing inventory complexity. |
1000V AC / 1500V DC maximum | Nearly double the voltage capacity of 600V-rated connectors. Supports higher-voltage distribution systems, battery storage, and renewable energy applications. |
Configurable cable gland system | Standard gland (CG-M4015-32) ships with two rubber bushings (Φ22mm and Φ33mm) covering cable Φ14mm to Φ33mm. Compact gland (CG-M4015) for mid-range cables. Optional M50 upgrade (CG-M5015-40) with adapter ring for larger cables. One connector body, multiple cable entry options. |
Phase-encoded SKU system | 8 housing colors with phase-specific SKU codes prevent cross-convention wiring errors. The same color can carry different phase assignments in different regions, and the SKU prefix makes the assignment unambiguous. |
Technical Specifications
Electrical
Current rating | 400A (120mm²) / 660A (240mm²) continuous |
Voltage | 1000V AC, 1500V DC maximum |
Test voltage | 4500V AC |
Short circuit rating | Up to 35.5 kA |
Insulation resistance | >5000 megaohms at 500V AC |
Contact resistance | 0.1 milliohms |
Mechanical
Set screw torque (Line) | 10.5 N/m minimum |
Nut torque (Panel) | 12-14 N/m maximum |
Cable gland (standard) | CG-M4015-32, M40 × 1.5, two bushings (Φ22mm + Φ33mm) |
Panel cutout | 42 × 42mm, 4 × Ø5.5mm fixing holes |
Mating cycles | 500 |
Materials
Housing | High impact-resistant thermoplastic, UL94-V0 |
Contact | Brass, silver-plated |
O-ring | Silicone (Drain connectors) |
Cotter pin | POM (Polyoxymethylene) |
Cable gland / bushing | Nylon and rubber (Line connectors) |
Nut and washer | Brass (Panel connectors) |
Dimensions by Configuration
Configuration | Total Length / Depth | Body Diameter | Key Dimension |
|---|---|---|---|
Line Drain (PFLD) | 190mm | Ø32.5mm | M40 cable gland |
Line Source (PFLS) | 170mm | Ø43.5mm | M40 cable gland |
Panel Drain (PFPD) | 72.2mm depth | Ø37.0mm | 55.0mm flange, Ø32.5mm thread |
Panel Source (PFPS) | 50.7mm depth | Ø42.5mm | 55.3mm flange, Ø43.5mm thread |
Panel cutout: 42 × 42mm for all panel configurations. Contact KUPO for detailed dimensional drawings (DXF/DWG).
Accessories and Companion Products
Cable Gland System
PowerFit line connectors use a configurable cable gland system that lets you match the seal to your exact cable diameter. The standard gland ships with every line connector. Compact and M50 options are available separately.
Part Number | Product | Cable Range | Notes |
|---|---|---|---|
CG-M4015-32 | Standard Cable Gland (M40) | Φ14–22mm + Φ23–33mm | Ships with two rubber bushings (Φ22mm and Φ33mm). Standard on all line connectors. |
CG-M4015 | Compact Cable Gland (M40) | Φ18–28mm | Single Φ28mm bushing. Smaller outer diameter for tighter builds. |
CG-M5015-40 | M50 Cable Gland (optional) | Φ32–40mm | For larger cables (240mm²+). Requires CG-M40-M50 adapter ring. |
CG-M40-M50 | Adapter Ring | N/A | M40 external thread to M50 internal thread. Enables M50 gland on standard PowerFit connectors. |
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Weatherproof Protective Covers
Part Number | Description | Notes |
|---|---|---|
PF-DCT-M | Male weatherproof protective cover | Maintains environmental protection on unmated Source connectors. |
PF-DCT-F | Female weatherproof protective cover | Maintains environmental protection on unmated Drain connectors. |
IP67 applies when mated. Use PF-DCT covers on any unmated connectors to maintain environmental protection across the full system. PDB-C1303 series cubic power distribution boxes (5 color variants) are also available for complete system builds. Contact KUPO for availability.
Certifications and Compliance
Certification | Detail |
|---|---|
TÜV Rheinland | Certified under ID 1111303479. Type Approved, Safety certified, Regular Production Surveillance. Independent third-party verification of product safety and quality. |
CE | CE marked. Meets applicable European health, safety, and environmental requirements. |
IP67 | Complete dust protection (6) and temporary water immersion up to 1 meter for 30 minutes (7). Applies when mated. Use PF-DCT covers on unmated connectors. |
Flame Class | UL94-V0. Highest vertical flame classification. Self-extinguishes within 10 seconds with no flaming drips. |
RoHS | Compliant with RoHS (Restriction of Hazardous Substances) Directive. |
REACH | Compliant with REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals). |
PowerFit carries TÜV Rheinland and CE certifications (European certification path). For applications requiring UL/cUL listing (North American certification), see the K-Lok 400A family (cRUus Listed, File E332947). For compliance documentation: contact KUPO Engineering.
Specs, Drawings, and CAD
Download the documents you need to complete a submittal package, mechanical design check, or procurement specification.
Document | Format | Download |
|---|---|---|
Product Family Datasheet | ||
Full Catalog Extract | ||
Installation and Assembly Guide | ||
2D Drawings (DXF / DWG) | ZIP | |
3D CAD Models (STEP / IGES) | ZIP | |
Panel Cutout Template (42 × 42mm) | DXF | |
Compliance Pack (TÜV, CE, RoHS) | ZIP |
Need a document not listed here? Contact us and we will prepare it for your submittal package.
Installation and Assembly
Always de-energize circuits before mating or unmating connectors.
Line Connector Assembly (6 Steps)
1. Loosen cable gland nut and remove gland body.
2. Thread cable through gland nut, then body.
3. Strip cable to spec (refer to datasheet).
4. Insert conductor into contact barrel, tighten set screw to 10.5 N/m minimum.
5. Seat contact assembly into housing until it clicks.
6. Reassemble cable gland and tighten for IP67 seal.
Panel Connector Installation (4 Steps)
1. Cut 42 x 42mm panel opening using template.
2. Insert connector from rear, align flange with 4 fixing holes.
3. Connect conductor to M12 threaded post, tighten brass nut to 12-14 N/m max.
4. Secure flange with 4 screws. Remove plastic end cap before first mating.
Frequently Asked Questions
Can I disconnect a PowerFit connector while the circuit is live?
No. PowerFit single-pole connectors are not rated for load-break disconnection. Pulling a PowerFit connector while current is flowing creates an electrical arc that damages contacts, degrades the housing, and risks burns, shock, or fire. At 400A the arc energy can cause immediate injury. Always de-energize at the breaker, verify dead with a voltage tester, then disconnect.
What does IP67 mean, and does it apply when the connector is unmated?
IP67 means complete protection against dust ingress (rated "6") and temporary water immersion up to 1 meter for 30 minutes (rated "7"). This rating applies only when mated. The silicone O-ring on Drain connectors creates the waterproof seal when a Source and Drain pair are connected. For unmated connectors, use PF-DCT-M (male) or PF-DCT-F (female) weatherproof protective covers to maintain environmental protection during storage or when one side of a circuit is not in use.
What is the difference between Source and Drain?
Source connectors have the male contact (pin) and the patent key-release pin for controlled disconnection. Drain connectors have the female contact (socket) and the silicone O-ring that provides the IP67 seal. Electric direction flows: Panel Source → Line Drain ↔ Line Source → Panel Drain. Source always mates with Drain. The key-release pin on Source connectors can be operated tool-free or with a small slotted screwdriver. A diagram is available at the top of this page.
Why does the same color appear in multiple SKUs (for example, 1BK, 2BK, and NBK are all black)?
PowerFit uses phase-encoded SKU codes where the prefix indicates the electrical phase assignment, not just the physical color. Black can be L1 (1BK, under North American NEC), L2 (2BK, under European IEC 60446), or Neutral (NBK, under Australian/old UK conventions). This system exists because the same physical color carries different phase meanings in different regional wiring standards. Ordering by phase-encoded SKU instead of color alone prevents dangerous cross-convention wiring errors. The phase tables on this page show which code matches your regional standard.
Does PowerFit carry UL/cUL listing?
PowerFit carries TÜV Rheinland certification (ID 1111303479), CE marking, and RoHS/REACH compliance. It follows a European certification path and does not carry UL/cUL listing. For applications that specifically require UL/cUL listing (common in North American bid specifications), KUPO offers the K-Lok 400A family, which is cRUus Listed under File Number E332947 to UL 1691. This means KUPO can provide a certified connector for every market requirement from a single supplier.
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Configuration help, compatibility confirmation, fleet pricing, and engineering documentation.
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