Wiring a Powerlet Deluxe Plug

Properly wiring a plug is more difficult than it seems at first. You strip a couple wires and screw them in the plug, then put the plug back together. That's basically it, but I found many tips along the way to make it easier and a first class install. Please read on before attempting this yourself. If you find this all too much, I will be happy to do it for you by making up a custom cable kit.

Here is the plug taken apart and the wires cut to length. Note that the best way to do this job is before the other end of the wires are fixed, so that their length can be changed by moving them through the sheathing. If you have the other end of this cable finished first, pay special attention to getting the wires, the stripping, and the sheathing exactly right. The sheathing cannot extend beyond the centre screw's post.

I got this great new thermal wire stripper and I've been waiting for a place to show it. Anyway, strip both wires the length of the mounting post only. Do not extend the wire past the posts. Try and get the insulation tightly against the posts, with the stripped part filling the posts completely. Strip 3/16 " will work.

Now tin the ends of the wires with your soldering iron. If you don't have one, skip this step. If you do, don't be lazy, just do it. It keeps the wire strands from being broken when they are screwed down tightly.

Tin just enough to cover all the strands. Too much and the wire won't fit into the plug's wire holders.

Now the rubber grommet must go on the wire, if it's not already installed. Note here that the grommet is going to be a tight fit on these rather heavy wires and sheath. If being waterproof is not needed, you can omit the grommet.

Here is how you can get the grommet over a rather large wire/sheath bundle. If it's not tight, it's not going to be weatherproof. This one was a very tight fit.

Now, loosen the wire locking screws almost completely. Note that the positive wire (red) goes into the darker brass coloured post. (on top here)

Insert the tinned wires. Make sure the black wire does not stick out beyond the post. It will not fit properly if it does. The red wire can extend a bit more into its post.

Tighten the screws snugly at this time but don't try and crank them up hard yet, you will only bend the post bracket.

Lay the wired unit into the shell and crank those wires up snugly. If you have smaller wires go easy, as you can break the strands if you tighten the screws too much on thinner wires. The wire clamp is shown here already in place, but you'll likely install that after securing the wires.

Getting the wire clamp on turned out to be a bear of a job, difficult to show or explain. Once you get both wires tightened and in position, you have to tighten up the wire clamp. (here on the left side of plug)

This strain relief clamp was removed to install these large wires, but you might be able to slip both wires and sheath under it if the screws are unscrewed almost fully. The grommet must be positioned before the strain relief is tightened.

Tightening the clamp screws fully, but not too much is a bit difficult. They do not like going in at a bit of an angle and a fat wire/sheath puts a bit of pressure on the screws. Once you get the screws started, turn the unit over and hold it solidly on a flat surface so you can crank these two screws up tight enough to hold the wire but not so much that crush them.

Keep turning the unit back over to check that the wires are clamped and will not move, but do not tighten the clamp too much. Keep both wires in the centre of the clamp where it is curved. Note that the grommet has to be in place to do this operation. Take your time here. This is an important step.

Note that the wire insulation is tucked down below the centre screw's plastic post, so that it won't be pinched when the body halves are tightly clamped together. Now, the top body half can be put in place.

Here the two halves are almost together. You must carefully work the grommet into position before clamping the halves together. Guide the rubber grommet into it's place on the top cover while lining up the body halves and squeezing them together.

Now, tighten up the body clamping screw snugly. Do not overtighten this screw!

You are done! That is one happy looking plug.

Did I mention that I make custom kits with pre-installed plugs? Go here.