Appleton Powertite® Series Instruction Sheet
330086-000
INSTRUCTION SHEET
instruction For instAllAtion And MAintenAnce oF powertite® series:
pin And sleeve receptAcles, plugs And cAble connectors (30, 60, 100 And 150 AMpere)
For use with copper conductors only
Electrical Rating
Maximum Voltage: 600 VAC at 50-400Hz, 250V DC; Maximum.
Continuous Current: 30, 60, 100 or 150 Amperes.
ApplicAtions
• Designed to supply power to portable or xed electrical
equipment such as motor generator units, welders, pumps,
compressors and similar apparatus.
• Ideal for use on shipping docks, ports and other “ship to
shore” applications.
• Suitable for use in locations where a watertight
enclosure is required.
• Rough usage construction.
FeAtures
A. Rugged. All components have copper-free aluminum
housings.
B. Two Grounding Styles. Copper grounding straps in
Style 2 receptacles and plugs (shown) ground thru shell
and extra pole. Style 1 thru shell only.
C. Convertible. Two screws secure receptacle insulator
block; one screw secures plug insulator block. Permits
easy conversion to reverse service (30, 60, 100A).
D. Watertight. Mounting box sealed with gasket. Receptacle
and connector seals with screw cap or plug. Plug sealed
when in receptacle or connector
E. Insulator Blocks. Provide high mechanical and dielectric
strength, very low “arc tracking”.
F. Positive Ground. Grounding detent springs assure
maintained ground contact.
G. Self-Aligning. “Floating” plug and receptacle contacts
automatically align.
H. ArcingConned. Contacts made and broken in snufng
chamber. In emergency, plugs can be withdrawn under
full rated loads (30A thru 100A). Positive polarization helps
prevent mismatching plugs.
I. Positive Contacts. Brass contacts have integral springs
for positive maintained electrical contact.
J. Clamping Ring, Plug. Neoprene gasketed, 30A, 60A,
100A, 150A plugs thread onto receptacle for watertight
union.
K. Positive Cable Clamp. Plugs supplied with neoprene
bushing and a reversible cable clamp for rm, watertight
t over a wide range of cable diameters. Locking screw
prevents Gland Nut from turning.
retAin this instruction sheet For
Future reFerence.
reAd instructions cAreFully And
with Full understAnding For sAFe
instAllAtion And operAtion.
coMpliAnces:
UL Standards 1682, 1686 (all) and 1010/1203 (plugs only);
CSA Specication C22.2 No. 182.1
Enclosure Type 3, 4, 4X
FIGURE 1
A
D
B
C
E
G
F
H
I
J
E
C
A
K
Style 2 Powertite Plugs, Receptacles and Cable
Connectors are equipped (since mid-1990) with contacts
designed to provide a safety polarization means called
“Controlled Length” contacts, as indicated on product
nameplate. This feature will not allow the plug grounding
contact (Style 2) to touch an energized receptacle “line”
contact in the event the plug becomes damaged and/or
loses its primary polarization means and/or is rotated into
the incorrect position.
Rev. J 4/15/10 Page 1
Except as expressly provided by Appleton Electric
(Appleton) in writing, Appleton products are intended for
ultimate purchase by industrial users and for operation
by persons trained and experienced in the use and
maintenance of this equipment and not for consumers or
consumer use. Appleton warranties do not extend to and
no reseller is authorized to extend Appleton’s warranties to
any consumer.
CAUTION
To prevent ignition of hazardous atmospheres do not use in
Class 1, Group F locations that contain electrically conductive dusts.
CAUTION
ACP series plugs may be mated with Powertite Series
Receptacles in ordinary locations and with the DBR,
MD2SR, JBR, EBR and EBRH Series Receptacles for
use in hazardous (classied) locations as dened in the
National Electrical Code and the Canadian Electric Code.
Portable utilization equipment connected to the ACP Series
plug must be approved for use in the intended location.
Equipment NOT approved for use in hazardous locations
as dened by the N.E.C. and C.E.C., connected to an ACP
plug must be used in non-hazardous locations. If used in a
hazardous area, the equipment must be approved for that
location, or the area must be purged of the hazard and
declared non-hazardous.
WARNING
Use cable with diameters within the specied range given in
TABLE B for any given grommet size and clamp orientation.
Failure to do so may result in over stressed wire terminations
which could cause the conductors to pull out of the contacts
and cause serious/fatal injuries due to electrocution or re.
WARNING
Do not modify these devices in any way.
Replace any missing or broken parts with proper replacements parts from Appleton Electric. Modication of these
devices or substitution of parts with non-standard parts may
result in serious/fatal personal injury from electrocution.
Plug is watertight when inserted in proper receptacle or
cable connector and the clamping ring is fully tightened.
instAllAtion instructions For powertite “Acp” plugs:
30A, 60A, 100A, 150A
FIGURE 2
CABLE
STEEL RING
7
GROMMET
6
CLAMPING
RING
8
WARNING
If any parts of the plug, receptacle or cable connector
appear to be missing, broken or show signs of damage;
DISCONTINUE USE IMMEDIATELY!
This condition could cause serious/fatal personal injury
due to electrocution and/or equipment damage. Repair with
proper replacement part(s) before continuing service.
WARNING
Electrical power must be turned “OFF” before and during
installation and maintenance. Failure to do so may result
in serious/fatal injuries due to electrocution.
HOUSING
GROUND STRAP
12
(Style 2 only)
INSULATOR BLOCK
9
ASSEMBLY
11
FEMALE
CONTACT
4
GLAND NUT
CABLE CLAMP
5
3
SET SCREW
1. Disassemble plug as shown in Figure 2 by removing
sleeve locking screw 1 and loosen set screw 3 (for
applicable models only), and unscrewing gland nut
4. It is not necessary to remove female contacts 11
from insulator block 9. In case of STYLE 2 insulator
block, make sure grounding contact with strap is in the
proper location. See Figure 4.
2. Strip the cable jacket and individual conductors per
Table “A”.
3. Select proper grommet 6 and cable clamp 5 orientation
per Table “B”.
Reversible cable
cl amps (j ust
remove screws, ip
over and replace
1st POSITION 2nd POSITION 3rd POSITION
Page 2 330086-000 Rev. J 4/15/10
SEALING WASHER
GROUND STRAP
SLEEVE LOCKING
1
SCREW
13
SCREW
(Style 2 Only)
2
SLEEVE
screws) permit wide cable range. Convenient in installations having different cable sizes. See Figure 8.
4. Slide gland nut 4, steel ring 7, proper grommet 6 and
housing 8 in that order back over cable.
5. Connect wires to proper terminals in insulator block
by loosening (but not removing) terminal pressure
screws on contacts. Then insert conductors including
all strands into contact terminals according to your
established wiring scheme. Tighten terminal pressure
screws to a torque value per Table C. (Conductors
must bottom in contact terminal well and insulation must extend below surface of insulator block.)
See Figure 3.
Continued on next page...
6. Position insulator block assembly 9 in sleeve 2. For
STYLE 2, attach ground strap 12 to sleeve 2 with
ground strap screw and torque in 25 in. lb. min. / 30
in. lb max. Screw the combination of sleeve and contact block assembly into housing 8 until the threaded
hole in sleeve 2 is aligned with the hole in housing
8. Thread in sleeve locking screw 1 including sealing
washer and torque to 30 in. lb. min. / 35 in. lb. max.
7. Slide grommet 6 and steel ring 7 up and as close to
housing as possible. Force cable into wiring cham-
ber to induce a minimum of 1/8 in. slack in the wire
between clamp and terminal. Screw gland nut 4 onto
housing 8 and torque per Table “C”. Finally torque the
set screw 3 (for applicable model only) in place at 10
in. lb. min. / 15 in. lb. max.
8. Refer to Table “B” and Figure 8 for correct cable clamp
orientation. Tighten cable clamp screws to 30 in. lb.
min. / 35 in. lb. max. Screws were lubricated at the
factory but if needed, relubricate with a good grade of
grease.
WARNING
A wire scheme must be followed so that the same
color wire is always put into the same numbered contact opening in all plugs, connectors and receptacles in
the system. This will help insure correct polarity for
the system and helps to eliminate possibilities for
equipment damage and/or personal injuries due to
electrocution or re.
FIGURE 3
CONDUCTOR INSULATION
BELOW THIS SURFACE
WIRE
(see Table A)
SCREWDRIVER/ALLEN WRENCH
TERMINAL
PRESSURE
SCREW
INSULATOR BLOCK
ASSEMBLY
instAllAtion instructions For powertite “Adr” receptAcles:
30A, 60A, 100A, 150A
FIGURE 5
ADR Spring Cover ADR Threaded Cap
ELECTRICAL TESTING
Do not connect to power until conducting the following
electrical tests.
• Test continuity of wiring to verify correct phasing and
grounding connections.
• Measure insulation resistance to be sure system does
not have any short circuits or unwanted grounds.
FIGURE 4
In STYLE 2, unmarked terminal cavities are for grounding contacts.
4 POLE
Front View
NOTE:
3 POLE
REAR VIEW OF
INSULATOR BLOCKS
Back View
1 Mounting
Bolts (4)
2 Gasket5 Set
Screws
Cover
Automatically
Closes
NOTE: Spring cover in open position for illustration only.
4 Spring
Cover
Receptacle
Insulator Block
6 Receptacle
Less Cover
Spring Cover and Screw Cover receptacles are threaded to
accept the clamping ring of the ACP plug. The ring threads onto
the receptacle to form a watertight assembly with plug in use
and also to prevent plug fallout. When the plug is withdrawn,
the gasketed Spring Cover automatically closes tightly against
receptacle opening providing weather-proof protection.
1. Follow instruction given in paragraphs 2 and 5 for “ACP”
plugs.
2. Insert insulator block assembly
7 into receptacle housing
6 and install two retaining screws with washers 8. Torque
to 30 in. lbs. min. / 35 in. lbs. max.
Mounting
Holes (4)
Grounding Strap
(Style 2 only)
7 Insulator Block
Assembly
Polarization Rib
8 Insulator Retaining
Screw (2) & Washer
3. Mount receptacle to previously installed back box using
mounting bolts 1 supplied with receptacle and torque to 30
in. lb. min. / 40 in. lb. max. Mounting screws provide electrical continuity between receptacle housing
box. Make sure gasket
2 is positioned correctly to make a
6 and back
watertight seal.
4. The spring cover can be positioned to open in any direction by loosening the set screws
cover
4, and retightening the set screws 5. Torque set
screws
5 to 7 in. lb. min. / 12 in. lb. max.
5, repositioning the spring
330086-000 Rev. J 4/15/10 Page 3
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