EGS Appleton Powertite 200 Series User manual

EGS Electrical Group • www.appletonelec.com • 800-621-1506 Rev. F 09/18/09 Page 1
330087
Instruction Sheet for Powertite®
Plug, Connector and Receptacle
Powertite®200 AmP Pin & Sleeve recePtAcleS,
cAble connectorS And PlugS: nemA 4X.
600 volt Ac, 250 volt dc. wire receSS diAmeter: .687”. wire Size rAnge: 250mcm - 4/0 And 3/0 - #4.
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 NEMA 4X
enclosure is required.
• Rough usage construction
• Available in two grounding styles:
Style 1 (3W, 3P and 4W, 4P) shell grounding only.
Style 2 (2W, 3P and 3W, 4P) Shell and extra pole
grounding.
Compliances
• UL Standards 1682.
• CSA Specications C22.2 No 42.
* Plug is NEMA 4X when clamp is fully tightened.
Powertite®technicAl dAtA:
reverSe Service, PolArizAtion, Pin And Sleeve deSign.
Applications
• Designed to supply power to portable or
xed electrical equipment such as motor
generators 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
weatherproof enclosure is required.
• Rough usage construction
• Available in two grounding styles:
Style 1 (3W, 3P and 4W, 4P) shell grounding only.
Style 2 (2W, 3P and 3W, 4P) Shell and extra pole
grounding.
Compliances
• UL Standards 1682.
• CSA Specications C22.2 No 42.
AJA Mounting Box
with Clamp Door
Receptacle
AJA Mounting Box
with Spring Cover
Receptacle
Plug Only*
Connector
Body Only*
Complete
Connector*
Ground Male
Terminal Assembly
Split Type
Contacts
Note: When ordering Reverse Service add - RS after catalog number.
Front Terminal
Block
Male Terminal
Ground Bar
Ground
Screw
Bushing
Crown
Style 1 (Only)
Ground Wire
Assembly
Plug Retaining
Ring
Retaining
Ring
Plug HousingHousing Cap Rear Terminal
Block
(Style 1)
330087 Rev. G 10/16

EGS Electrical Group • www.appletonelec.com • 800-621-1506Page 2 330087 Rev. G 10/16
Powertite®200 AmP Pin & Sleeve PlugS: nemA 4X.
600 volt Ac, 250 volt dc. wire receSS diAmeter: .687”. wire Size rAnge: 250mcm - 4/0 And 3/0 - #4.
Plug and
Connector Cable
Dia. Range
Cable Dia. Grommet
I.D.
Clamp
Position Clamp No.
.875 to 1.906
.875 to 1.062 1-1/32 -1- 304350
1.062 to 1.281 1-9/32
1.281 to 1.561 1-19/32 -2- 304350
1.562 to 1.906 1-29/32
1.875 to 2.500 1.875 to 2.187 2-3/16 -3- 304045
2.187 to 2.500 2-1/2
Terminal Recess Conductor Size Type Conductor
0.687 Dia.
250 MCM General wires
4/0 Flexible & extra
exible cable
* 0.687 Dia. with Stainless
Pressure Plate Included
(see page 5)
3/0 to 1/0 Flexible & extra
exible cable
* Option: Cat. No. PTK200WA3 and PTK200WA4 (see page 5)
0.687 Dia. with Copper
Pressure Plate #1 to #4 Flexible & extra exible cable
WARNING: A wire schematic must
be followed so the same color wire is
always put into the same numbered
contact openings in all plugs, connectors
and receptacles in the system. This will
insure the correct polarity for the system
and eliminates possibilities for equip-
ment damage and/or personal injuries.
1. Disassemble as shown by removing screw (1),
loosen setscrew (2) and unscrew cap (4), remove
retaining ring (3) and terminal block (9).
2. Strip the proper cable as shown: (also applies to
connector and receptacle).
3. Prepare cable clamp (5) and select the proper
grommet (6) as shown:
Reversible cable clamp (just loosen screws and ip
over) permits wide cable range.
4. Slide cap (4) with clamps (5), steel ring (7), proper
grommet (6) and housing (8) over the cable.
5. Insert Wires into the proper terminals and tighten
For disconnect use only - not for current rupture
Phase
Motor Wire/Pole
Motor Horsepower
120 VAC 240 VAC 480 VAC 600 VAC
1-Phase 2W, 3P 60 120 160
3-Phase 3W, 3P; 3W, 4P or 4W, 4P 60 120 160
For emergency interrupting - maximum horsepower
1-Phase 2W, 3P 15 30 40 40
3-Phase 3W, 3P; 3W, 4P or 4W, 4P 20 40 50 50
set screws securely.
6. Slide terminal block assembly (9) into the
housing (8) aligning the hole in the ground
bar with the hole in the housing. Replace the
at head screw (1) and tighten securely.
7. Place the grommet (6) and steel ring
(7) in the back of the housing and tighten
the cap (4) until grommet (6) is tightened
around the cable and tighten the setscrew
(2). Tighten the clamps (5) screw securely.
Ground Screw
Cable Clamps (5)
Cable
Steel Ring (7)
Grommet (6)
Flat Heat Screw (1)
Style 1 (only)
Ground Wire
Assembly
Cap (4) Set Screw (2) Housing (8)
Terminal Block Assy (9)
Retaining
Ring (3)
Grounding Bar
(Style 2 only)
Reference Guide Of Horsepower Ratings
For Use With Single Motor Application

EGS Electrical Group • www.appletonelec.com • 800-621-1506 330087 Rev. G 10/16 Page 3
Powertite®200 AmP Pin & Sleeve recePtAcleS: nemA 4X.
600 volt Ac, 250 volt dc. wire receSS diAmeter: .687”. wire Size rAnge: 250mcm - 4/0 And 3/0 - #4.
Powertite®200 AmP Pin & Sleeve connector: nemA 4X.
250 volt dc, 600 volt Ac. wire receSS diAmeter: .687”. wire Size rAnge: 250mcm - 4/0 And 3/0 - #4.
1. Remove the rear polarizing ring (1). Slide out the terminal block (2).
2. Follow paragraphs No. 2 and No. 5 for the plugs.
3. After wiring, slide terminal block assembly (2) in the back of housing (3). Replace the polarizing ring (1).
4. Tighten the angle adapter mounting bolts (4) to 50 to 70 in.-lbs. torque.
5. Tighten the receptacle mounting bolts (5) to 120 to 150 in.-lbs. torque.
1. Disassemble, as shown by loosening setscrews (1) and (2),
unscrew clamp cap (4) and housing cap (9), remove polarizing
plate (8), at head screw (12) and terminal block assembly (10).
2. Follow instructions shown on paragraphs No. 2 and No. 3 for the
plugs.
3. Slide clamp cap (4), steel ring (7), proper grommet (6), housing
cap (9) and polarizing plate (8) over the cable.
4. Follow instructions shown on paragraph No. 5 for the plugs.
5. Slide terminal block assembly (10) into the housing (11) aligning
the hole in the ground bar with hole in the housing, Put in at head
screw (12), tighten securely and put in polarizing plate (8).
6. Tighten housing cap (9) on the housing (11) and tighten
setscrew (1) securely.
7. Place the grommet (6) and steel ring (7) on the back of housing
cap (9), tighten the clamp cap (4) until the grommet (6) is tightened
around the cable and tighten the setscrew (2) and cable clamps (5)
securely.
Ground Male
Terminal Assembly
(Style 2 only)
Rear Polarizing
Ring (1)
Ground
Screw
Terminal Block
Assy (2)
Housing (3)
AJA
Mounting Box
Receptacle
Only*
Terminal Block
Assy (10)
Grommet (6)
Housing Cap (9)
Clamp Cap (4) Style 1 (only)
Ground Wire
Assembly
Style 2
Ground Screw
Ground Male
Terminal Assembly
Flat Head
Screw (12)
Housing (11)
Cable
Clamps (5)
Set Screw (2)
Steel
Ring (7) Set Screw (1) Polarizing Plate (8)
Complete
Connector
Connector
Body Only

EGS Electrical Group • www.appletonelec.com • 800-621-1506
Powertite®technicAl dAtA:
grounding StyleS, mAXimum wire SizeS.
PLUG – Equipment grounding
conductor is wired directly to
a solderless lug which is con-
nected to the plug housing with a
pressure connector. All terminals
are “current carrying.”
RECEPTACLE - Two detent
spring clips engage the ground-
ed plug housing on plug inser-
tion - grounded plug shell makes
contact with receptacle ground
spring before line and load poles
are engaged. Grounding path
is maintained until after current-
carrying contacts disengage. All
terminals are “current carrying.”
Standard Service
PLUG - Equipment grounding
conductor is not only connected
to the solderless lug in the plug
housing, but also to an extra
grounding pole. Grounding pole
has copper alloy grounding
jumper strap that connects to
plug housing.
RECEPTACLE - Two detent
spring clips engage the ground-
ed plug housing on plug inser-
tion. Jumper from extra ground-
ing pole is electronically con-
nected to a screw on receptacle
housing. Longer grounding pole
“makes rst and breaks last.”
Reverse Service
Receptacles Mounted on AJA and AJC Boxes
A B C D E F G H
8.00 10.75 6.75 9.50 14.00 15.25 3.75 1.88
dimenSionS:
Powertite®200 AmP Pin & Sleeve recePtAcleS,
PlugS, cAble connectorS, And mounting boXeS.
Receptacle
No. Poles A B C D E F
3 3.25 5.63 4.19 8.00 6.63 6.56
4 3.63 5.63 4.56 8.00 6.63 6.56
Connector Body
No. Poles A B C
3 13.00 4.19 5.38
4 13.00 4.56 5.75
Plug
No. Poles A B C D E
3 11.94 7.81 3.81 3.75 6.44
4 11.94 7.81 4.19 4.13 6.81
Style 2
Shell and Extra
Pole Grounding
Page 4 330087 Rev. G 10/16
Option
for AJB

EGS Electrical Group • www.appletonelec.com • 800-621-1506 330087 Rev. G 10/16 Page 5
Powertite®200 AmP PreSSure PlAte.
For 3/0, 2/0 And 1/0 wire Size* with receSSed terminAl only
oPtionAl AcceSSorieS For wire Size* #1 to #4 - SPeciAl APPlicAtion
cAtAlog number PtK200wA3 (3 PlAteS) And PtK200wA4 (4 PlAteS)
1. Prepare components as shown in gure 1.
2. Insert stripped end of wire into terminal.
3. Insert pressure plate into terminal so that set screws, pressure plate and wire are aligned (gure 2).
4. Tighten set screw securely (80-100 in-Ibs).
1. Prepare components as shown in gure 3.
2. Insert copper plate into terminal.
3. Insert stripped end of wire into terminal so that set screws, wire and copper plate are aligned (gure 4).
4. Tighten set screw securely (50-60 in-Ibs).
* Caution: Check National Electrical Code for proper wire size and application.
1. Pressure Plate
4. Hex Set Screw
4. Hex Set Screw
2. Stripped Wire
Recessed Terminal
3. Terminal
2. Stripped Wire
1. Copper Plate
3. Terminal
Figure 3
Figure 1
Figure 4
Figure 2

EGS Electrical Group • www.appletonelec.com • 800-621-1506Page 6 330087 Rev. G 10/16
1. With both wing nuts fully tightened, loosen the RIGHT
wing nut that secures the receptacle cover ¼ turn and
position both wing nuts as shown in Figure 1.
Figure 1
2. Slide the locking bar to the right and slip the locking
bracket under the left wing nut and over the at washer.
3. Slide the locking bar to the left side.
Figure 2
4. Slip the locking bracket under the right wing nut and
over the at washer as shown in Figure 2. Tighten
the wing nut ¼ turn until it is parallel with the locking
bracket
5. Slide the locking bar in place until it is ush with both
ends of the locking bracket as shown in Figure 3.
Figure 3
6. Install padlock(s) in one or more of the ve 11/32”
(8.9mm) padlock holes provided.
oPtionAl AcceSSorieS For Powertite®200 And 400 AmP Pin & Sleeve recePtAcleS
inStAllAtion inStructionS For cAtAlog numberS:
PtlocK2004 - Powertite 200 AmP 3 & 4 Pole locKing Kit
PtlocK4004 - Powertite 400 AmP 4 Pole locKing Kit

EGS Electrical Group • www.appletonelec.com • 800-621-1506 330087 Rev. G 10/16 Page 7
200 AmP ground lug For Style 1 recePtAcle
To Assemble Grounding Lug
1. Locate threaded hole on polarizing plate (1).
2. Insert the brass screw (3) through the top of lug (2).
3. Line-up edge of plate (1) with at on lug (2).
4. Thread screw into plate until tight.
5. Thread set screw (4) into lug (2).
To Connect Ground Wire To Lug
1. Prepare wire by stripping 3/4”from the end of the wire (wire size range: #2-4/0).
2. Loosen the set screw enough to t the wire in the lug.
3. Tighten set screw securely (50-60 in-lbs).

EGS Electrical Group • www.appletonelec.com • 800-621-1506Page 8 330087 Rev. G 10/16