When the cable doesn’t fit, and you need a solution… FAST…
GO TO THE GREAVES
ADAPTER
ZONE!
In today’s world, there are more and more unusual and complex situations
that require careful design solutions and product selection.
The Greaves Adapter Zone provides guidelines, examples, and
tips to help you select the best solution to your adapter requirement.
www.greaves-usa.com
ADAPTER PROBLEMS COME IN VARIOUS SHAPES AND SIZES.
HERE ARE SOME TYPICAL SITUATIONS.
• An equipment move or change calls for extension of cables.
• Cable runs were upsized to counteract voltage drop, or the
neutral is upsized to improve power quality.
• Aluminum cables (used instead of copper because of cost
or availability) need splice, transition, or termination. Only
aluminum connectors must be installed on the aluminum wires.
• Multiple wire-ports on a circuit breaker are too closely spaced to
allow the cables to fit.
• The cabinet does not have enough space to accommodate
bending and fitting cables into the lugs.
Adapter situations usually fall into one of these categories:
Splice/reduce: When you need to splice/reduce cables that are different from each other
• Splice a copper wire to a smaller copper wire – select from compression (CRK, ND, AC-R) or mechanical (PBS, ABS)
• If one or both wires are aluminum – choose a dual-rated aluminum splice; either compression (AC-R, ASC-T) or
mechanical (PBS, ABS)
• Splice aluminum to a smaller copper wire – select from dual-rated compression (AC-R, ACK) or dual-rated
mechanical (ABS, PBS)
• Transition from copper flex/DLO to copper Class B/THHN cable – request a custom copper compression splice.
Consult factory.
• Transition from aluminum wire to a copper flex cable (such as DLO or weld) – request a custom compression
splice. Consult factory.
Terminate: When you need to terminate a cable into a lug where it does not fit, or is not of the appropriate
material or stranding:
• Terminate a copper Class B cable into a mechanical lug, but the cable is too large to fit – select compression
adapter (PT-R, CRK).
• Terminate an aluminum cable into a copper/bronze lug – select a compression pin adapter (PT).
• Terminate a copper flex/DLO cable into a mechanical lug – select adapter PT-FX.
• Terminate a copper cable into a lug which needs a larger wire – step up for the larger lug with a compression
reducer (CRK, ND-R), or select a mechanical splice/reducer (PBS, ABS). Then install a larger jumper to fit the lug.
Or consult factory regarding a special “reverse adapter” with larger pin.
Multiple cables: When you need to fit multiple cables into closely-spaced wire-ports on a circuit breaker:
• With copper cable, often the PT-R (for Class B) or PT-FX (for flex/DLO) adapters will allow spacing close enough,
because the barrels are about the same thickness as the cable jackets themselves.
• Use adapters with offset pins (PTO), so each adapter can be rotated (before installation) to allow the wires to be
more closely spaced, so they will fit into the wire-ports.
• Splice smaller jumpers onto the runs and locate the splices away from the lug so the smaller jumpers can be
bunched to fit into the multiple wire-ports. On copper cables, use splice/reducers such as CRK or ND-R. For
aluminum cables, when when the jumper is copper, use compression splice AC-R or kit ACK-R.
Limited space in switchgear cabinet: In compact switchgear cabinets, sometimes there is not enough
space for a bend in Class B cable, so flex/DLO is used for the tighter bend capability. Then, an adapter is needed
to terminate the flex/DLO into the lug. Select a PT-FX adapter, or consult factory for other special design
configurations, such as adapters manufactured with 45º or 90º bends.
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Collect all the information bef
Your materials:
and types?
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What are the wire materials
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Aluminum Class B stranding ___
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Copper Class B stranding ___
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the existing lugs?
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What material and type are
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Dual-rated aluminum ______
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Copper/bronze _________
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Compression ______
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Aluminum or copper/bronze ___
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Fit into a defined space ___
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Availability (when nee
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Tooling available _________
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Approval needed _________
General Design Rules:
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: 860-664-4546
PHONE: 860-664-4505 | FAX
TOLL FREE: 800-243-1130 |
www.greaves-usa.com
Example – Splicer/Reducer:
You need to splice aluminum 250MCM wire to copper #4/0 Class B wire, in-line. Per the General
Design Rules, you must use an aluminum connector on the aluminum wire. The splice must also be
dual-rated to accept the copper wire.
With compression splices
• O ne choice is a #AC250R40 one-piece dual-rated aluminum splice/reducer to accommodate
both wires.
• A nother choice would be #ACK250R40 two-piece splice kit, which includes a #ASC250T
aluminum barrel splice and a #CRA250-40 copper insert to size one end of the barrel down for
the #4/0 copper wire.
With mechanical splices
• One choice is a # PBS250 dual-rated insulated splicer.
• Another choice would be a #ABS250 which is also dual-rated, but not insulated.
Example – Terminate with pin adapters:
• When the cable is 600MCM copper Class B, but the switchgear lug only accepts up to 500MCM,
use adapter #PT600R500. For non-standard reductions, select a compression kit (CRK) to create
your own adapter.
• For 313DLO, select PT313FX350 which has a 350MCM Class B pin. For non-standard reductions,
consult the factory.
• When the cable is #4/0AWG copper, but the lug only accepts 500-250MCM, step up for the larger
lug with a compression reducer (#CRK250-40, ND-R) that accepts both sizes, or select a mechanical
splice/reducer (#PBS250, #ABS250). Then install a jumper of the larger wire to fit the lug. Or,
consult the factory regarding a special “reverse” adapter PT-R with pin larger than the barrel.
Example – A multi-cable circuit breaker with closely spaced wire-ports:
You need to terminate multiple oversized cables into the closely spaced wire-ports on a circuit breaker,
but the wires do not group closely enough to fit into the wire-ports:
• For copper wires, usually an adapter such as Greaves PT-R Reduce®™ (for Class B stranding) or PT-FX
Shoo-Pin™ (for flex/DLO stranding) will allow grouping close enough (because the barrels are similar
in thickness to the cable jackets, rather than thicker as with aluminum adapter barrels).
• I f those do not fit, or if the wires are aluminum, try adapters with offset pins (PTO) which allow
rotation before installation for closer grouping.
• O r, splice smaller jumpers onto the runs and locate the splices away from the lug, so the jumpers
can be grouped to fit the lug. For copper cable, splice with a kit (CRK) or one-piece adapter (ND-R).
For aluminum cable, use a multi-piece kit (ACK-R) or one-piece splice (AC-R).
Example – Switchgear cabinet has limited space:
You need to terminate 500MCM copper into a lug which is only 7 inches from the cabinet wall. But
500MCM Class B cable has a minimum bend radius of 8 inches, so 535DLO flex cable is selected for the
tighter bend radius. With a PT535FX500 Shoo-Pin adapter, the assembly fits into the confined space.
CONNECTORS FROM THE GREAVES
ADAPTER ZONE
The Greaves Adapter Zone includes numerous types of adapters, splices, and lugs in many sizes,
to give you a wide variety of potential solutions:
Compression Pin Adapters:
• PT-R Reduce®™ all-copper pin adapters for Class B cable
• PT-FX Shoo-Pin™ all-copper pin adapters for flex/DLO cable
• PT Pin Adapters with aluminum dual-rated barrel and stranded copper pin
• PTA All-aluminum dual-rated adapters with concentric pin
• PTO All-aluminum dual-rated adapters with offset pin
Compression Reducer/Splices require the user to provide
a short “pin” wire:
• CRK kit for copper-to-copper includes barrel splice and CRA insert(s)
• ND-R Step-Down one-piece for copper-to-copper are normally for Class B
stranding, and can also be custom-made for flex/DLO wire
• ACK kit for aluminum-to-copper with aluminum barrel and CRA insert for
the copper
• AC-R all aluminum dual-rated one-piece dual-rated
CRA Copper compression reducer adapter inserts can:
• Adapt a splice or lug to accept a smaller copper wire.
• Be installed in either copper or aluminum compression barrels, but only
when the wire is copper.
Aluminum dual-rated mechanical splice/reducers for
Class B stranding:
• PBS (insulated)
• ABS (non-insulated)
Greaves offers many types of multi-cable lugs and connectors.
They are:
• Cold-fit types for direct-burial (UPP, US-K, UFK)
• Heat shrink (HWA) with adhesive to insulate splices for direct burial.
GREAVES CAPABILITIES
Since 1947 Greaves has been a trusted supplier of
electrical connectors to the electrical construction
trades. After beginning in New York, the company
moved to Connecticut in 1950 and to a site in Guilford,
Connecticut in 1954. Over the years, Greaves added
manufacturing facilities and capabilities to produce
mechanical lugs and splices, compression lugs and
splices, and numerous types of grounding clamps.
In 2007 Essex Products Group of Centerbrook,
Connecticut acquired Greaves, and in 2008 relocated the
factory to nearby Clinton, Connecticut. This relocation
allowed consolidation for quick manufacturing,
stocking, and customer service.
With a variety of in-house metal-working and machining
processes, and with extensive stocks of raw materials
and finished products, Greaves can quickly supply both
standard and special products. Greaves capabilities include
designing custom products and modifying standard
products for specific applications. As a full-line supplier,
Greaves inventories over 4000 different items.
For further information, contact:
TOLL FREE: 800-243-1130
PHONE: 860-664-4505
FAX: 860-664-4546
www.greaves-usa.com