On Set Power Distribution

The essentials of on set power distribution

Film sets run on electricity. Cameras, LED fixtures, HMIs, practicals, compressors, video village, and data carts all draw power every minute of the day. On set power distribution ties those needs into a stable source, then routes electricity safely through a hierarchy of equipment so every department gets what it needs without tripping breakers or creating hazards.

A typical system starts with a generator or utility tie in, steps through a main disconnect or distro, then branches out through feeder cable to sub distros and lunchboxes close to the action. From there, technicians deploy stingers and power drops to individual devices. Labels, color coding, and a clean layout let crews trace a circuit quickly, fix issues fast, and move gear without guesswork.

The goal is simple. Deliver the right voltage and current to each load while keeping voltage drop, heat, and fault risk within safe limits. That means correctly sized cable, protected connections, and careful placement that respects foot traffic, vehicle flow, and water.

Key concepts include:

• Total load calculation and surge headroom
• Three phase balancing or even loading on split phase
• Grounding and bonding for fault clearing
• Selective coordination so upstream protection is not nuisance tripped
• Weather protection and strain relief at every connection

Planning, safety, and calculations that prevent outages

Planning begins with a load sheet. Departments estimate continuous current draw and peak inrush for each device. The electric team then calculates total amperage, adds diversity factors, and reserves headroom for changes. For long cable runs, they check voltage drop based on wire gauge, distance, and current, then upsize conductors or move power closer to the set to stay within tolerance.

Load calculation and power factor

Lighting does not always present a purely resistive load. Ballasts, drivers, and power supplies can alter power factor, which means current at the generator can be higher than simple wattage math suggests. Crews look at nameplate ratings, consult ballast specs, and consider harmonics when sizing distribution. LED loads have improved, but large arrays and dimmers still benefit from de rated calculations and generous headroom.

Generator and tie in practices

If utility power is not available or reliable, productions use a film grade generator with stable voltage regulation and low acoustic signature. Placement matters. Keep the generator on level ground, downwind, and at a distance that manages noise while minimizing cable length. Tie ins to a house panel or camlock must be performed by qualified personnel using listed equipment, lockout tagout, and a clear line of responsibility. Ground rods, bonding jumpers, and neutral handling follow the authority having jurisdiction and the electrical code that governs the venue.

Grounding, GFCI, and bonding

Grounding ensures faults clear rapidly. Bonding connects all conductive parts so there is no dangerous difference in potential. GFCI and RCD protection add life safety for wet zones and handheld tools. Portable distros should have intact grounding paths, verified with a meter before the day starts. Any damaged connector, cracked insulation, or warm lugs are removed from service until repaired.

Other safety habits that pay off:

• Keep connections off the ground with stands or mats
• Use strain relief on feeder and drops to protect terminations
• Cover walkways and drive lanes with rated cable ramps
• Post signage for hot sets and energized equipment
• Maintain a power log and label every circuit

Equipment, layout, and workflow on a working set

Distribution is only as good as the gear. Feeder cable carries high current from the source to the main distro. Quality camlock connectors with intact springs and clean contacts prevent heat at mating points. Main distros provide breakers, meters, and multiple output formats so crews can feed sub distros, lunchboxes, and specialty devices without adapters that create weak links.

Sub distros should live close to the work but out of harm’s way. Elevate where possible. In wet or dusty conditions, use enclosures with appropriate ingress ratings and keep spares sealed until needed. For cabling, heavier gauge is chosen for long runs to control voltage drop. For practicals and sensitive electronics, power conditioning and line filtering reduce noise that can travel on the neutral and interfere with audio or video.

Lighting now leans heavily on LED, which reduces load and heat compared to legacy sources. Still, dimming networks, wireless receivers, and data cables need clean layout to avoid interference. Keep power and data crossings at right angles where practical, separate runs when possible, and avoid coiling cable that can become an inductor and add heat.

Weather changes everything. Plan for rain with covers, elevated connections, and dry zones for gear. In cold, cables stiffen and connectors lose flexibility. In heat, ampacity derates and connectors can creep. Regular thermal checks during lunch and wrap help catch issues before they turn into downtime.

Efficient workflow shows up in the details:

• Stage a spare sub distro for fast moves
• Pre label runs by location and scene
• Standardize color codes for phases and departments
• Keep a repair kit with fuses, lamps, connectors, and tools
• Log every change to the plan so night shoots and second units inherit a clean system

H2 backups for continuity include a secondary source plan. Uninterruptible power supplies on critical devices bridge momentary transitions. Battery based systems can float on the rig and support video village or data wrangling without generator noise. When the plan anticipates these pivots, production can seize golden hour without waiting for a reset.

How OZK Customs supports dependable on set power

When your set needs a mobile base that delivers clean electricity, integrated storage, and organized distribution, a purpose built vehicle becomes a force multiplier. OZK Customs designs and builds production support vans that house lithium battery banks, pure sine inverters, shore power inputs, and labeled distro so crews plug in and go. Quiet operation and smart charging let you run sensitive loads at call time, then recharge from utility, a generator, or solar between setups.

For teams that travel, we configure secure rack space for lighting and distro, weather resistant exterior inlets, and cable management that keeps the work zone clear. We also add work lighting, scene lighting, and communications so departments can collaborate without wrestling power. Whether you need a full custom build or a focused upfit around your existing platform, we tailor the layout to your load sheet and shooting style.

Looking for a platform you can finance and outfit for production life. See our recreational and adventure focused vehicles to understand options and layouts that convert smoothly into production support. Then schedule a spec session so we can translate your gear list into a safe, code conscious power plan.

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Power is the heartbeat of a set. If you want a mobile command center that rolls in ready to energize lights, monitors, and data with clean distribution and safe routing, talk to our team. We will translate your amperage, cable runs, and generator strategy into a refined van that speeds setup and protects your crew. Share your load sheet and timeline, and we will craft a solution that works on day one and scales with your productions.